Introduction
Reference Introduction chapter titleDescription
This chapter contains basic information about this document and the related TetraPak® equipment.Document Information
Document Information. Alternative 2. Not valid for Tetra Pak D&T Industrial Base EngineeringBefore interacting with the equipment, carefully read the instructions in the applicable documentation pertinent to the activity.Note that the document may apply to several variants and describes all designs. There may therefore be descriptions of systems and details that are not found on your equipment.Equipment that is shown in the illustrations may, depending on the design, differ from your equipment.Any item that is named specifically in this document is to be considered a designated item for the equipment. Designated items are verified by the TetraPakGroup for use with the equipment.The TetraPakGroup will not be held responsible for any damage, loss, injury, or death that is caused by not following the instructions in the documents that are provided with this equipment. Also, the TetraPakGroup will not be held responsible for the above due to failure to use designated items that are specified in the documents that are provided with this equipment.The ”Public” classification given for this document means that the document is public information. As public information, the document is created to be provided to receivers outside the TetraPakGroup.Delivered Manuals
Manuals delivered with this equipment:EM
The Electrical Manual provides technicians with information about the equipment’s electrical system.IM
The Installation Manual provides technicians with information required to safely install the equipment.MM
The Maintenance Manual provides technicians with information on maintaining the equipment.OM
The Operation Manual provides the operator with information on handling and operating the equipment before, during, and after production.OM - Package Checks
The Operation Manual - Package Checks provides the operator with information on testing the packages.SPC
The Spare Parts Catalogue provides the information necessary to order spare parts from the TetraPakGroup.TeM
TeM. Alternative 3The Technical Manual provides information that is needed during the crate handling process when the crate is equipped with a metal folder.This includes- the data and information concerning the crate and crated equipment
- the information concerning lifting machinery and lifting accessories
- the procedures for receiving, opening the crate, and unpacking the equipment
TeM - FSC
The Technical Manual - Food Safety Chart provides information necessary to make a Hazard Analysis and Critical Control Plan (HACCP) for the production line containing the equipment.Document Accessibility
The documents delivered with the equipment are necessary for the correct installation, use, and maintenance of the equipment on an ongoing basis. Make sure that these documents remain accessible with the equipment over the life time of the equipment. If the equipment is transferred or re-sold, these documents must accompany the equipment and be made available to the subsequent holder or user of the equipment.Page Numbering

- Consecutive page number
- Total number of pages
Note: The letters UP may appear before the Consecutive page number if the user manual includes update pages. The Consecutive page number and the Total number of pages of update pages do not follow the existing sequential page numbering of the user manual.
- UP
- Consecutive page number
- Total number of pages
Typographical Conventions
Typographical Conventions. Alternative 2Physical buttons on the operator panel, emergency stop devices, program steps, and program tasks are given in CAPITAL LETTERS.Names of buttons, entry fields, menu items, or other objects that allow the user to control the user interface are given in Courier.Information that is displayed on the user interface, is to be repeated in the document, but is not used to control the user interface, is given in COURIER CAPITAL LETTERS.Cross-references are underlined.Symbols
Symbols used in illustrations. | A pointer arrow indicates the position of an object. |
 | A zoom arrow indicates that an object view is enlarged. The arrow points towards the enlarged view of the object. |
 | A rotation movement arrow indicates rotational movement of an object. The arrow points in the direction of rotation. |
 | A straight movement arrow indicates movement of an object. The arrow points in the direction of movement. |
Detail Levels in Instructions
This document contains instructions with either one or two levels of detail. The instructions presented in two levels of detail consists of two parts. The Quick Reference part presents the instruction with a condensed level of detail describing how to perform the instruction. The Detailed Procedure part presents the same instruction on a detailed level.
- Quick Reference part
- Detailed Procedure part
Intended Use of the Equipment
Intended Use of the Equipment.- TT/3 variant XH with IC is to produce the Tetra Top package families Base, Midi, and Mini.
- TT/3 variant XH is to produce the Tetra Top package families Base, Midi, Mini, and Micro.
- TT/3 variant AD (ASD) is to produce the Tetra Top package families Base, Midi, and Mini filled with high acid beverage (still drink). The packages can be stored in ambient conditions.
- TT/3 variant ADY is to produce the Tetra Top package Mini filled with yoghurt with fruit content. The packages can be stored in ambient conditions.
- TT/3 variant ASCM is to produce the Tetra Top package family Midi filled with sweetened condensed milk. The packages can be stored in ambient conditions.
- TT/3 variant AW is to produce the Tetra Top package family Base and Midi filled with water. The packages can be stored in ambient conditions.
All other use is prohibited. The TetraPakGroup will not be held responsible for injury or damage if the equipment is used for any other purpose than the intended use described above.Manufacturer
This TetraPak® equipment is manufactured byEU Declaration of Conformity
EU Declaration of Conformity. Alternative 1.A copy of the EU Declaration of Conformity (DoC) can be found in the Installation Manual.UK Declaration of Conformity
UK Declaration of Conformity. Alternative 1.A copy of the UK Declaration of Conformity (DoC) can be found in the Installation Manual.Identification
Identification. Alternative 2.3-A Compliance
The USA/Canada version of this equipment complies with the 3-A Sanitary Standards for Formers, Fillers, and Sealers of Containers for Fluid Milk and Fluid Milk Products. The applicable version number of the standard can be found on the machine plate.EAC Compliance
This equipment complies with the regulations of the Eurasian Customs Union.China RoHS2 Compliance
This equipment may contain one or more of the following substances: Pb, Hg, Cd, Cr6+, PBB, and PBDE.The Environmental Protection Use Period is 25 years.The Hazardous Substances Disclosure Table can be found in the General chapter in the IM, or in the General section in the Installation Instructions chapter in the TeM.Identification Plate
The illustration below shows an example of the identification plate and its location on the equipment. The identification plate carries data needed when contacting the TetraPakGroup concerning this specific equipment.
The illustration shows the non USA/Canada variant and without
IC.
- Name and address of manufacturer
- Equipment name and material number
- Year and month of manufacture
- CMiM mark (if applicable)
- RoHS2 mark (if applicable)China
- 3-A mark (if applicable)
- 3-A standard number (if applicable)
- Ukrainian mark (if applicable)
- Ukrainian conformity assessment body number (if applicable)
- UK Approved body number (if applicable)
- UKCA mark (if applicable)
- EAC mark (if applicable)
- EU Notified body number (if applicable)
- CE mark
- Equipment serial number (when available)
CSUValid for the machine variant with
IC.
- Name and address of manufacturer
- Equipment name and material number
- Year and month of manufacture
- CMiM mark (if applicable)
- RoHS2 mark (if applicable)China
- 3-A mark (if applicable)
- 3-A standard number (if applicable)
- Ukrainian mark (if applicable)
- Ukrainian conformity assessment body number (if applicable)
- UK Approved body number (if applicable)
- UKCA mark (if applicable)
- EAC mark (if applicable)
- EU Notified body number (if applicable)
- CE mark
- Equipment serial number (when available)
GSU- Name and address of manufacturer
- Equipment name and material number
- Year and month of manufacture
- CMiM mark (if applicable)
- RoHS2 mark (if applicable)China
- 3-A mark (if applicable)
- 3-A standard number (if applicable)
- Ukrainian mark (if applicable)
- Ukrainian conformity assessment body number (if applicable)
- UK Approved body number (if applicable)
- UKCA mark (if applicable)
- EAC mark (if applicable)
- EU Notified body number (if applicable)
- CE mark
- Equipment serial number (when available)
TTCU- Name and address of manufacturer
- Equipment name and material number
- Year and month of manufacture
- CMiM mark (if applicable)
- RoHS2 mark (if applicable)China
- 3-A mark (if applicable)
- 3-A standard number (if applicable)
- Ukrainian mark (if applicable)
- Ukrainian conformity assessment body number (if applicable)
- UK Approved body number (if applicable)
- UKCA mark (if applicable)
- EAC mark (if applicable)
- EU Notified body number (if applicable)
- CE mark
- Equipment serial number (when available)
Valid for: Equipment with Vision Unit 3764870-0100
- Name and address of manufacturer
- Equipment name and bill of material number
- Year and month of manufacture
- CMiM mark (if applicable)
- RoHS2 mark (if applicable)China
- 3-A mark (if applicable)
- 3-A standard number (if applicable)
- Ukrainian mark (if applicable)
- Ukrainian conformity assessment body number (if applicable)
- UK Approved body number (if applicable)
- UKCA mark (if applicable)
- EAC mark (if applicable)
- EU Notified body number (if applicable)
- CE mark
- Equipment serial number (when available)
Electrical Equipment Marking
TT/3The illustration below shows an example of the electrical equipment marking and its location on the equipment. The electrical equipment marking specifies the electrical characteristics for the equipment at the connection point.
Valid for: Other Countries
- Electrical document number
- Electrical document BoM
- Serial number
- Full-load current
- Short-circuit capacity
- Maximum supply source impedance
- Supply voltage
- Phase
- Frequency
Valid for: USA and Canada
- Electrical document number
- Electrical document BoM
- Serial number
- Type
- Full-load current
- Largest motor
- RMS symmetrical
- Enclose Type rating
- Supply voltage
- Phase
- Frequency
- Short-circuit current rating
Valid for: Equipment with Vision Unit 3764870-0100
Valid for: Equipment with CAU
- Electrical document number
- Electrical document BoM
- Serial number
- Full-load current
- Short-circuit capacity
- Maximum supply source impedance
- Supply voltage
- Phase
- Frequency
Electrical Equipment Marking
TT/3The illustration below shows an example of the electrical equipment marking and its location on the equipment. The electrical equipment marking specifies the electrical characteristics for the equipment at the connection point.
- Electrical document number
- Electrical document BoM
- Serial number
- Type
- Full-load current
- Largest motor
- RMS symmetrical
- Enclose Type rating
- Supply voltage
- Phase
- Frequency
- Short-circuit current rating
Valid for: Vision Unit 3652291-0100
Valid for: Equipment with CAU
- Electrical document number
- Electrical document BoM
- Serial number
- Type
- Full-load current
- Largest motor
- RMS symmetrical
- Enclose Type rating
- Supply voltage
- Phase
- Frequency
- Short-circuit current rating
Delivered Design Label
TT/3The illustration below shows an example of the delivered design label and its location on the equipment. The delivered design label lists information tracking any rebuilding done to the electrical design, and any alterations done in the electrical cabinet and to related electrical components.The delivered design label is filled in by the person performing the rebuilding or alteration.
TT/3
Valid for: Equipment with Vision Unit 3764870-0100
Orientation
The following illustration shows the orientation of the equipment. This orientation information is used throughout this manual. The arrows indicate the flow of material.
The illustration shows the non USA/Canada variant and
XH with
IC.
In order to define a particular point on or inside the machine, the machine has been given special designations. The machine has two sides, designated side 1 and side 2. The sides are divided into side 1:1, 1:2, 2:1 and 2:2. See the following illustration.
Other countries The machine as seen from the front.

USA and Canada The machine as seen from the front.
The following illustration shows the main groups of the equipment for a TT/3 filling machine.
First illustration is valid for Other CountriesSecond illustration is valid for USA and Canada- ASU
- Carton section
- LFU
- CAU
- Package section
- Filling section
- Electrical cabinet
The following illustration shows the extra equipment for a TT/3 filling machine.
The illustration shows the non USA/Canada variant and
XH with
IC.
- Granulate container
- GSU
- CSU
- Vision unit
- TTCU

The illustration shows the non USA/Canada variants without
IC.
- Granulate container
- GSU
- TTCU
- SRU
Packaging Material
- Always protect your packaging material against contamination.
- Always keep the doors to the filling room (area) closed. To prevent contamination via air streams, never open a window when the equipment is in production.
- Never clean the floors or the equipment in the filling room (area) when the equipment is in production.
- Compressed air used for cleaning purposes is to be used only for cleaning filters and should only be used outside of the filling room (area) or in the final folder compartment of the packaging machine.
- If splicing of the packaging material is applicable, prepare the splicing as late as possible.
- Disinfect your hands before touching anything that may come into contact with the product.
- Keep your hands clean.
- Always wear some type of hair protection (cap or hairnet) and clean clothes (preferably white).
- Do not wear a watch, ring, necklace, earrings, or any other exposed jewellery.
Waste Management
Separate all materials and components in a safe and environmentally responsible way. Recycle or dispose of the materials and components according to national legislation or local regulations. In the event no such legislation or regulations exist, recycle or dispose of the materials and components in a safe and environmentally responsible way. If there is any uncertainty regarding what material a component is made of, contact the TetraPakGroup. Use a certified (ISO 14001 or similar) scrapping or waste handling company.For further details of disposal of chemicals, see the Hazardous Substances section in the Safety Precautions chapter.Separation of Materials and Components
- stainless steel (panels and doors)
- cast iron (frames)
- brass
- glass (windows, and so on)
- rubber (seals, O-rings, and so on)
- nylon and other plastics
- electrical cables
- hydraulic hoses
- central lubrication hoses
- pneumatic hoses
- electrical components
- batteries
- mercury (UV-lamp)
Electrical Components
Electrical components and batteries may need to be disposed of in special waste management systems. Follow national legislation or local regulations.Packaging and Additional Material
Remaining packaging material and additional material such as strips, caps, tops, corrugated cardboard, and plastic film wrapping shall be sent for recycling or disposed of according to national legislation or local regulations.Procedures
Procedures. Alternative 2. Not valid for Tetra Pak SCO Industrial Base Performance.- The hyphens indicate that it is a procedure heading. The example shows a heading for Procedure number 3 in Section 1.5.
- The text after the second hyphen tells what type of procedure it is. Check, Change, and Set are common procedure types.
Maintenance procedures in this document are connected to the TetraPak Maintenance System, TPMS. See the TPMS section.Procedure Start Table
- Equipment Status shows actuator status, program step, and any other equipment status necessary to begin the procedure. If an actuator status is omitted, this implies that the status of the actuator is not relevant for the procedure. If an actuator status is "LOCKED in OFF position", this implies that the supply must be turned off according to the prescribed lockout procedure in the Maintenance Manual.
- Special Equipment shows a list of personal protective equipment and special tools that are not normally carried by a service technician, but are needed in the procedure.
- Consumables shows items, such as lubricants, which are required to perform the procedure. Consumables do not include replacement parts.
- SPC Reference refers to the Bill of Material number within the SPC where the spare parts to be used during the procedure, if applicable, are listed.
- KIT SPC Reference refers to the Bill of Material number within the KIT SPC where the spare parts to be used during the procedure, if applicable, are listed.

- Equipment Status
- Special Equipment
- Consumables
- SPC Reference
- SPC ReferenceKIT
TPMS
TPMS is the maintenance methodology to handle all maintenance-related work processes from development and the whole life cycles for TetraPak® equipment. The TPMS methodology is reliability-centred (best industry practice) and aims at finding the right combination of predetermined, condition-based, and corrective maintenance. In maintenance, the challenge is to find the right level of investment in parts and labour effort to achieve the desired performance, quality, and reliability. Thanks to TPMS, it is possible to create maintenance plans with a good balance between what is invested and what it received in return.How TPMS Works
Users around the globe continuously feed the system with maintenance data. The data is continuously evaluated and then utilised to improve maintenance recommendations and customer-specific scheduling of maintenance tasks. TPMS takes a holistic approach to maintenance by including the actions needed to contribute to plant efficiency. With this advanced maintenance management tool, the maintenance checklists are designed to include latest updates of our recommendations to meet the demands for fewer unscheduled stops, reduced waste, and less interference with production.TPMS Maintenance Recommendation Overview
With the TetraPakGroup's extensive experience of managing maintenance on TetraPak® packaging lines, together with our advanced maintenance management tools, we can support you in tailoring the right maintenance plans (checklists) to follow the maintenance system in a consistent way. Using TPMS is a foundation to having your equipment run at its best. Checklists can be managed and delivered directly from your local TetraPak service station. In the checklist you will find information concerning what tasks shall be done and when they shall be done. Furthermore, the document reference will give guidance as to how to perform the work. The document references are MM, SPC, OM, RM, EM, and TeM.Note: The layout of the checklist is subject to change.For those customers that intend to set up their own maintenance system and plans, the TetraPakGroup can on a upon-request basis provide a maintenance recommendation overview for the specific equipment, including tasks required to keep the equipment in good condition. The recommendation will be provided free of charge for up to a year after delivery.The following items can be found in the maintenance recommendation overview:| Task Code | Trade | Task Action | Task Description | Document Reference | Interval |
| Number of the task | Skill required to perform the task | Check, Change, Turn, and so on | Work description | Where info can be found on how to perform this task | When the task shall be performed |
The TetraPakGroup's Maintenance recommendations are continuously updated and improved based on user feedback.Note: Contact the local TetraPak® office for additional information and support regarding TPMS.Assistance and Inquiries
Assistance and Inquiries. Alternative 2. Not valid for Tetra Pak SCO Industrial Base Performance.For assistance when operating this equipment, or other inquiries, comments, or suggestions, contact a TetraPak® representative to get support and to file a query in the TetraPak issue resolution system (QuTI-P).Safety Precaution Instructions
Read and understand this manual before using the equipment.Failure to follow safety precautions and instructions can result in death or serious injury.
Safety Messages Description
A safety message is always accompanied by a safety alert symbol and a signal word.The safety alert symbol is used to alert about potential personal injury hazards. To avoid hazards, obey all safety messages that follow this symbol.The following safety alert symbols and signal words are used in this document to inform the user of hazards. | Danger indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. |
| Warning indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. |
| Caution indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices. |
| Caution without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage. |
Personnel Requirements
Note: Personnel includes all persons working on or near this equipment.Only skilled or instructed persons are allowed to work with Tetra Pak® equipment.Skilled Person
A skilled person must have relevant education and experience to enable him or her to identify hazards, analyse risks, and avoid hazards which electricity, machinery, chemicals, other energies, and supply systems on this equipment can create.Skilled persons must meet local regulations, such as certifications and qualifications for working with these energies and systems.Instructed Person
An instructed person must be adequately advised or supervised by a skilled person. The skilled person enables the instructed person to identify hazards, analyse risks, and avoid hazards which electricity, machinery, chemicals, other energies, and supply systems on this equipment can create.Safety Signs
Damaged or missing safety signs.Safety signs are used to indicate safety hazards. If the signs are missing or damaged, they can not fulfil this function. Replace all missing or damaged safety signs immediately.
Safety signs are attached to the equipment. The table below lists all the signs that are used, and illustrations show their locations on the equipment. Each position number refers to two standards of a safety sign in the table, but only one is used on the equipment.- Make sure that each safety sign is legible and in its correct position after installation and maintenance.
- Replace all missing or damaged safety signs immediately.
| Pos | ISO Standard | ANSI Standard |
| 1 | | |
| Moving part can crush and cut.Do not operate with guard removed.Follow lockout procedure before maintenance. |
| 2 | | |
| Hazardous voltage.Will shock, burn, or cause death.Follow lockout procedure before maintenance. |
| 3 | | |
| Chemical hazard.Corrosive and oxidising chemical. Could cause death or serious injury. Read Safety Precautions in Operation Manual (OM) before handling hydrogen peroxide. |
| 4 | | |
| Hot surface.Do not touch.Follow lockout procedure before maintenance. |
| 5 | | |
| Fall hazard.Be careful when using stairways and ladders. |
| 6 | | |
| Hazardous residual voltage on capacitors.Will shock, burn or cause death.Disconnect power and wait 5 minutes before opening.Follow instructions for safe work practices. |
| 7 | | |
| Hazardous voltage.Can shock, burn, or cause death.Read Maintenance Manual (MM) before using this socket outlet. |
| 8 | | |
| Hazardous voltage could be present with power supply disconnector switched off.Can shock, burn, or cause death.Orange conductors supplied from an external source.Follow lockout procedure before maintenance. |
| 9 | | |
| Chemical burn hazard.Wear personal protective equipment. |
| 10 |  |  |
| Chemical burn hazard, Alkali.Contact with chemicals could be hazardous to health.Wear personal protective equipment. |
| 11 |  |  |
| Chemical burn hazard, Disinfectant.Contact with chemicals could be hazardous to health.Wear personal protective equipment. |
| 12 |  |  |
| Chemical burn hazard, Acid.Contact with chemicals could be hazardous to health.Wear personal protective equipment. |
| 13 | | |
| Laser Radiation.Do not stare into beam.Class 2 laser product. |
| 14 | | |
| Hazardous noise.Risk of impaired hearing.Wear hearing protection. |
| 15 | | |
| UV Radiation Hazard.Protect eyes & skin from exposure to UV light. |
| 16 | | |
| Do not reach in.Moving parts may cause injury.Follow instructions for safe work practice. |
| 17 | | |
| Inhalation hazard from chemicals and fumes.Can cause irritation to mucous membranes and the respiratory tract.Follow instructions for safe work practices. |
| 18 | | |
- Read and understand manual before operating this machine. If manual is missing, contact Tetra Pak.
- Do not operate this machine unless doors are closed and all guards are in place.
|
| 19 | | |
| Read Operation Manual (OM) before using this equipment.Failure to do so could result in death or serious injury. |
Locations of Safety Signs
Ladder

Safety sign on the ladderThis sign is only valid for the non USA/Canada version.
ASU

The illustration shows the USA/Canada variant and
AD (ADY,
ASD,
ASCM, and AW).* Valid for the USA/Canada variant.Safety signs on the
ASU, side 1. The signs are equally placed on side 2.Safety signs for hazardous voltage (2) are applied on all electrical connection boxes.
Carton Section

The illustration shows variant
AD (
ASD,
ASCM and
AW).Safety signs on the carton section, side 1. The signs are equally placed on side 2.Safety signs for hazardous voltage (2) are applied on all electrical connection boxes.
LFU

The illustration shows variant
XH with
IC.Safety signs on the
LFU, side 1. The signs are equally placed on side 2.Safety signs for hazardous voltage (2) are applied on all electrical connection boxes.
CAU
Valid for TT/3 OAO
Safety signs (1) on the
CAU, side 1. The signs are equally placed on side 2.Safety signs for hazardous voltage (2) are applied on all electrical connection boxes.
CSU

Safety sign on the
CSU.
Vision Unit

Safety sign on the Vision Unit.
Valid for: Vision Unit 3652291-0100
Package Section


Safety signs on the package section, side 1. The signs are equally placed on side 2.Safety signs for hazardous voltage (2) are applied on all electrical connection boxes.
Filling Section

* Valid for the USA/Canada variant.Safety signs on the filling section, side 1. The signs are equally placed on side 2.Safety signs for hazardous voltage (2) are applied on all electrical connection boxes.
Electrical Cabinet

Safety signs on the electrical cabinet.
GSU

Safety signs on the
GSU.
TTCU

Safety signs on the
TTCU.
SRU
Valid OM/IM, MM/EM for ADY (Taishan)
Safety signs on the
SRU.
Protective Devices
There are different kinds of protective devices designed to ensure safe use of the equipment. See the sections below.Hazardous zones.Hazardous zones are safeguarded and provided with protective devices. Do not inch or run this equipment if any protective device is inoperative.
Change inoperative components of the safety system immediately.For the locations of safeguards and/or other protective devices not mentioned in this section, see the Maintenance Manual.Emergency Stop
Hazardous voltage.Hazardous voltage remains ON after activating an emergency stop.Will shock, burn, or cause death.
Emergency stop devices are used to stop this equipment immediately in a hazardous situation. Learn the positions of all emergency stop devices and how to use them.Instructions for a normal production stop are included in the Stop chapter of the Operation Manual.Emergency Stop Buttons
Push one of the EMERGENCY STOP buttons to stop this equipment immediately.The location of each EMERGENCY STOP button is shown by an arrow.
Valid for: Other CountriesThe illustration shows the
XH with
IC variant.
Valid for: USA CanadaThe illustration shows the
XH with
IC variant.
Valid for: Equipment with CAU
CSU
GSU
The illustration shows the non-USA Canada variant
TTCU
Valid for: Version 1 and Version 2
SRUEmergency Stop Wires
Pull one of the Emergency stop wire to stop this equipment immediately.The location of each EMERGENCY STOP wire is shown by an arrow.
- Emergency stop wire
Valid for: Other countiesThe illustration shows the
XH with
IC variant.
Valid for: USA and CanadaThe illustration shows the
XH with
IC variant.
Safeguards
Moving machinery parts.Never defeat or bypass the interlocking devices.
Movable guards, for example, doors and covers leading to hazardous zones, are fitted with interlocking devices where required. These devices are usually electric safety switches that are parts of the safety system and must never be defeated, bypassed, or otherwise made inoperative.Where movable guards (doors) are equipped with means to be locked in a nonclosed position, any person with the intention to preside, for any reason, behind such a guard must lock the guard in the nonclosed position by use of a padlock.Note: For work on the electrical equipment, the electrical power must also be disconnected.Equipment damage.The equipment can be damaged if it is not stopped in the correct way. Never stop this equipment by opening a movable guard, for example, a door or cover, equipped with an interlocking device.
The location of each interlocking device is shown by an arrow.
Valid for: Other Countries
Valid for: USA and Canada
Corners and edges.Close the doors, guards, or parts of the equipment unless they must be open during work.
Burn hazard.Parts of the equipment protected by guards may be hot after operation. Allow components to cool down or use personal protective equipment.
After installation and maintenance, and before this equipment is inched or run, check that all safeguards are in place and that they operate correctly.Indicating Tower
- A Red light indicates a hazardous condition. This is a situation that requires immediate action.
- A Yellow light indicates an abnormal or impending critical condition. This is a condition calling for action by the operator.
- A Blue light indicates that operator action is required.
- A Green light indicates a normal condition.

First illustration shows the Other Countries variantSecond illustration shows the USA Canada variant
- Red light
- Yellow light
- Blue light
- Green light
Warning Lamp CIP and SIP
A Red light indicates when CIP or SIP has started. The light turns off 25 minutes after the cleaning or sterilisation is done.
Valid for: Other countries
- Red light
Valid for: USA and Canada
- Red light
Warning Lamp when Ready for Automatic Restart
A Green light together with a flashing Blue light indicates that the packaging machine is ready for an automatic restart. This means that the machine stops feeding new paper arks automatically for a maximum of 10 minutes, due to a fault elsewhere on the production line. If the fault is resolved within ten minutes, the packaging machine automatically restarts production and shows only a green light; otherwise, the packaging machine steps down to Heating and shows only a blue light.
First illustration shows the Other Countries variantSecond illustration shows the USA Canada variant
- Red light
- Yellow light
- Blue light
- Green light
Indicating Tower CSU
Valid for TT/3 OAO- A Red light indicates a hazardous condition. This is a situation that requires immediate action.
- A Yellow light indicates an abnormal or impending critical condition. This is a condition calling for action by the operator.
- A Blue light indicates that operator action is required.
- A Green light indicates a normal condition.
The light stops flashing and remains lit when the alarm is acknowledged. After the fault is corrected or the operator takes the appropriate action, the warning light turns off.
- Red light
- Yellow light
- Blue light
- Green light
Indicating Tower GSU
- A Red light indicates a hazardous condition. This is a situation that requires immediate action.
- A Yellow light indicates an abnormal or impending critical condition. This is a condition calling for action by the operator.
- A Blue light indicates that operator action is required.
- A Green light indicates a normal condition.
The light stops flashing and remains lit when the alarm is acknowledged. After the fault is corrected or the operator takes the appropriate action, the warning light turns off.
- Red light
- Yellow light
- Blue light
- Green light
Indicating Tower TTCU
- A Red light indicates a hazardous condition. This is an emergency situation that requires immediate action.
- A Yellow light indicates an abnormal conditions. This is impending critical condition calling for action by the operator.
- A Blue light indicates that operator action is required.
The light stops flashing and remains lit when the alarm is acknowledged. After the fault is corrected or the operator takes the appropriate action, the warning light turns off.
- Red light
- Yellow light
- Blue light
Indicating Tower SRU
- A Green light indicates that the machine is ready for production.

- Green light
Audible Alarm
The Audible alarm produces a warning signal every time this equipment is about to start. The warning signal sounds for approximately three seconds prior to starting to alert personnel.
The first illustration shows the Other Coutnries variantThe second illustration shows the USA and Canada variant
- Audible alarm
Safe Manual Handling
Use mechanical lifting aids whenever possible. If mechanical lifting aids are not available, do not attempt to lift loads over 23 kg without the assistance of a colleague. Avoid lifting below knee height and above shoulder height. If it is necessary to lift from the floor, follow the instructions below to reduce the risk of back and disc injuries.- Use safety shoes and be sure that the surface of the floor is not slippery.
- Get close to the load.
- Take a wide stance and find the best positions for your feet.
- Bend your hips and knees, and use your leg muscles.
- Keep the load close to your body.
- Do not twist your body while moving the load.
- Take small steps when turning.
In order to reduce the risk of injury to discs and back muscles, be careful to not bend or twist your back when lifting. Keep the load close to your body to reduce the strain on your back.To reduce the ergonomic risks to each individual operator, job rotation is recommended, so that recovery and variety are provided.Personal Protection
This section applies to all personnel at all times when this equipment is in operation. For special personal protective equipment required when handling hazardous substances, see the Hazardous Substances section.Entanglement
Risk of crushing and cutting.Do not wear jewellery or loose clothing when working on or near the equipment. Restrain long hair with, for example, clips or rubber bands.Moving parts in the machine can entangle jewellery or clothes.
Hazardous Substances
Chemical hazard.Always read and follow the instructions in the safety data sheet supplied by the manufacturer or local supplier, when handling chemicals.Contact with chemicals can cause death, serious injury, or illness.
- the safety data sheet is available
- preparations have been done to ensure that the stated safety measures in the safety data sheet can be followed
- the locations of the first aid equipment are learned in order to act immediately in case of an accident
Disposal of Chemical Substances
Always read and follow the disposal instructions in the safety data sheet supplied by the manufacturer or local supplier.- disposed of according to the instructions immediately after use
- not used as disposal containers for other chemicals in order to avoid uncontrolled chemical reactions within the container
Hydrogen Peroxide (H2O2)
Chemical hazard.Always read and follow the instructions in the safety data sheet supplied by the manufacturer or local supplier, when handling chemicals.Contact with corrosive chemicals can cause serious injury, or illness.
In both liquid and gas states, hydrogen peroxide may cause irritation or damage if it comes into contact with skin, mucous membranes, eyes, or clothes. Call for medical attention immediately if there is an accident.Liquid hydrogen peroxide in concentrations of less than 1% is generally considered harmless to humans.Consult the instructions on the label of the tank or container.Emergency Procedures
If there is an accident involving hydrogen peroxide, rinse the affected area as soon as possible with large amounts of water. Eyes
- wash the eyes thoroughly with lukewarm water for 15 minutes (keep eyelids wide apart)
- call for medical attention immediately
Skin
- rinse immediately with plenty of water
- call for medical attention immediately if skin burns appear
- thoroughly wash the clothes before wearing them again
Inhalation
- leave the affected area and get some fresh air
- call for medical attention if the symptoms get worse
Ingestion
- do not attempt to cause vomiting
- drink large amounts of lukewarm water to dilute the peroxide
- call for medical attention immediately
Personal Protective Equipment
- protective goggles (for instance, TP No. 90303-11), tight fittingIf there is a risk of splashes, a visor is a suitable complement
- protective gloves made of neoprene (for instance, TP No. 90303-12), nitrile, or butyl rubber
- protective apron (for instance, TP No. 90303-13), or protective suit when handling larger amounts
- protective shoes or boots made of PVC, PE plastic, or rubber
- proper respiratory equipment, if ventilation is insufficient
Handling of Hydrogen Peroxide
Chemical hazard.Avoid any contamination of hydrogen peroxide.Sudden and violent chemical reaction.
Hydrogen peroxide can react very suddenly and violently in combination with many compounds, or if it is contaminated. Never pour surplus hydrogen peroxide back into the original container. There is a risk of a violent decomposition liberating oxygen and heat, with a big increase in volume due to the oxygen generated by the peroxide decomposition. This will cause a large overpressure if the contaminated hydrogen peroxide is in a closed container. If the integrity of the container fails, this could result in a dangerous hazard.Ensure that equipment used for handling and diluting hydrogen peroxide is clean before it comes in contact with hydrogen peroxide. Pumps or other equipment used for handling hydrogen peroxide must be used for this purpose only and must be manufactured from appropriate materials, such as stainless steel 316 L, glass, polyethylene, or teflon. After use, make sure that all peroxide residue is rinsed away.If hydrogen peroxide is spilled, dilute it with large amounts of water. Dispose of the diluted hydrogen peroxide according to local regulations.Chemical hazard.Never wipe up hydrogen peroxide with materials such as rags or paper as these may self-ignite several hours after contact. If there is a fire, spray with large quantities of water.Risk of self-ignition.
Storage of Hydrogen Peroxide
Chemical hazard.Keep the container upright and fitted with its proper ventilation cap. If there is a fire, cool all containers by spraying them with large quantities of water.Containers may become overpressurised if they are not properly ventilated. If the integrity of a container fails, this could result in a dangerous hazard.
Hydrogen peroxide decomposes much faster with increasing temperature. There is a risk of a container becoming overpressurised at high temperatures, since the ventilation cap cannot release the gases produced quickly enough. If the integrity of the container fails, this could result in a dangerous hazard.Hydrogen peroxide must be stored in the original container delivered by the supplier. Keep the container upright and fitted with its proper ventilation cap, which allows oxygen to escape. Otherwise there is a risk of overpressurisation of the container due to violent decomposition of the peroxide. If the integrity of the container fails, this could result in a dangerous hazard.Make sure that the container is always properly closed.Commercial food-grade hydrogen peroxide has been stabilized to inhibit the catalytic decomposition effects of metals and other impurities, but it can decompose into oxygen and water if it is exposed to heat or contaminated.- cool, clean, and well ventilated
- shielded from direct sunlight
- kept free from combustible materials
Disposal of Hydrogen Peroxide
Always read and follow the disposal instructions in the safety data sheet supplied by the manufacturer or local supplier.Ultraviolet Light
Ultraviolet light.The ultraviolet lamp must only be operated when it is in its normal operating position and protected by its safeguard.Can cause eye or skin burns.
An ultraviolet lamp is protected by an interlocking guard, such as a door or cover.Ultraviolet light damage is cumulative. Extended exposure may cause illness. Exposure to ultraviolet light should be avoided.Hot surfaces.The assembly housing and components around the ultraviolet light assembly are hot. Allow components to cool down before maintenance.May cause burns.
The location of each ultraviolet light is shown by an arrow.
Valid for: Other countries
Valid for: USA and Canada
Definition of Lockout Procedure
A lockout procedure is a procedure to put each necessary energy isolating device in its safe position to prevent the energisation of the equipment, such as when a maintenance procedure should be carried out.A lockout is the use of a device, for example, a padlock, to make sure that an energy isolating device cannot be operated.An energy isolating device is a mechanical device that physically prevents transmission or release of energy, such as an electrical supply disconnecting device.When a utility should be LOCKED in the OFF position according to the Equipment Status row of a Procedure Start Table, the lockout procedure for that utility is applicable.A detailed instruction for the specific lockout procedure(s) for this equipment is found in the General chapter of the Maintenance Manual, or the General section of the Maintenance Instructions chapter of the Technical Manual.Electrical Supply
Hazardous voltage and moving machinery.The electrical supply disconnecting device must be in position O (OFF) and secured with a lock before any work with the equipment that requires the electrical supply to be disconnected. See the Machine Status row in the table at the beginning of the applicable procedure.
Note: The key to the lock must be removed by the technician and retained in his/her possession until all work is completed.Hazardous voltage can be present with the electrical supply disconnecting device in position O (OFF).Circuits identified by orange-coloured conductors are not disconnected by the main electrical supply disconnecting device. The location of the electrical supply disconnecting device of these circuits is described in the Maintenance Manual procedures that include work on these types of circuit.
Certain procedures may require that the electrical supply disconnecting device is in position | (ON). These exceptions are clearly stated in the manuals.The illustration shows the electrical supply disconnecting device and its location.
The illustration shows the non USA/Canada variant and
XH with
IC.
The illustration shows the vision unit electrical supply disconnecting device and its location.
Valid for: Equipment with CAU
Valid for: Mecman machines
The illustration shows the vision unit electrical supply disconnecting device and its location.
Valid for: Equipment with CAU
Valid for: Festo machines
The illustration shows the vision unit electrical supply disconnecting device and its location.
Valid for: Equipment with Vision Unit 3764870-0100
Valid for: Equipment with CAU
The illustration shows the CSU electrical supply disconnecting device and its location.
Valid for: Equipment with CAU
The illustration shows the GSU electrical supply disconnecting device and its location.The illustration shows the TTCU electrical supply disconnecting device and its location.The illustration shows the SRU electrical supply disconnecting device and its location.
Valid for: SRU Micro
The illustration shows the SRU electrical supply disconnecting device and its location.
Valid for: SRU Version 1 and 2
Residual Voltage
Hazardous voltage.After the electrical supply disconnecting device is turned to position O (OFF), residual voltage remains in the capacitor circuits. Wait five minutes before opening the enclosure containing these circuits. Ensure that no residual voltage remains on the capacitors before touching them.Will shock, burn, or cause death.
Electrical Cabinet
Electrical Cabinet [2]Hazardous voltage.Parts behind doors to the electrical cabinet may be live. The electrical supply disconnecting device must be turned to position O (OFF) and secured with a lock before performing maintenance inside the electrical cabinet.Will shock, burn, or cause death.
Note: The key to the lock must be removed by the technician and retained in his/her possession until all work is completed.When opening the doors to the electrical cabinet, live parts inside the cabinet are disconnected via an interlock.Make sure that the electrical cabinet doors are closed after working inside the electrical cabinet. Doors with locks must be locked.The location of each electrical cabinet is shown by an arrow.
The illustration shows the non USA/Canada variant and
XH with
IC.

The illustration shows the non USA/Canada variant and
XH without
IC.
Socket Outlet
Hazardous voltage.Read the Maintenance Manual before using this socket outlet.Can shock, burn, or cause death.
The Socket outlet is connected to a Residual current device to protect users against electrical shock if there is an earth fault in the connected equipment. The residual current device must be tested each time before the socket outlet is being used. See the Maintenance Manual for test procedure.The USA/Canada version of the machine does not have a Residual current device but the Socket outlet must be tested. See the MM for test procedure.The illustrations show the socket outlet, the residual current device, and their locations.
- Residual current device
- Socket outlet
- Power side
- Control side
The illustration shows the Socket outlet, the Residual current device, and their location in the CSU electrical cabinet.
Only valid for variant
XH with
IC.
- Socket outlet
- Residual current device
The illustration shows the Socket outlet, the Residual current device, and their location in the GSU electrical cabinet.
- Socket outlet
- Residual current device
The illustration shows the socket Socket outlet, the Residual current device, and their location in the TTCU electrical cabinet.
- Socket outlet
- Residual current device
Air Supply
Compressed air and moving machinery.Close the main air valve and lock it, and safely release compressed air from the air system before any work with the equipment that requires the air supply to be closed. See the Equipment Status section of the Procedure Start Table.
Note: The key to the lock must be removed by the technician and retained in his/her possession until all work is completed.Certain procedures may require air supply systems to be on. These exceptions are clearly stated in the manuals.The illustrations show the Main air valve, the Lock, and their location.
The first illustration is valid for Other Countries variants.The second illustration is valid for USA and Canada variantsThe illustration shows the
XH with
IC variant.
- Main air valve
- Lock
Locate the air supply valve to the GSU before starting any work on the equipment.Note: The location of the air supply valve to the GSU is specific for each site.The illustration shows the TTCU main air valve and its location.The illustration shows the Vision Unit main air valve and its location.The illustration shows the Vision Unit air valve ramp and its location.
Valid for: Vision Unit 3652291-0100
Valid for: Equipment with CAU
Steam Supply
Hot steam can cause scalds.Close the main steam valve and lock it, and safely vent all steam pressure from the steam system before any work on parts with steam, such as pipes and valves, that requires the steam supply to be closed. See the Machine Status section of the Procedure Start Table.Pressurised steam can be discharged unexpectedly.
Note: The key to the lock must be removed by the technician and retained in his/her possession until all work is completed.Certain procedures may require steam supply systems to be on. These exceptions are clearly stated in the manuals.The illustrations show the Main steam valve, and its location.
The first illustration is valid for Other Countries variants.The second illustration is valid for USA and Canada variantsThe illustration shows the
XH with
IC variant.
- Main steam valve
Hot parts can cause severe burns.Pipes, valves, and other parts containing steam can be extremely hot. Do not touch hot parts.
The illustration shows the TTCU main steam supply valve and its location.Water Supply
Water under pressure.Close the main water valves before any maintenance that requires the water supply to be closed. See the Machine Status section of the Procedure Start Table.
Certain procedures may require water supply systems to be on. These exceptions are clearly stated in the manuals.The illustrations show the main circulating cooling water Valve, circulating cooling water and the main hot water external cleaning water Valve, hot water external cleaning, and their locations.Sections of the system can also be closed separately with the Ball valve.
- Valve, circulating cooling water
- Valve, hot water external cleaning
- Ball valve
The illustration shows the location of the internal drinking water shut-off valves in the carton section and package section.Locate the drinking water supply to TT/3 before starting any work on the equipment.Note: The location of the drinking water supply to TT/3 is specific for each site.
First illustration valid for Other Countries.Second illustration valid for USA and Canada. The illustrations show the TTCU main drinking water supply valve and its location.Gas Supply
High pressure gas.Close the main nitrogen valve to the gas dosing system before any maintenance that requires the nitrogen supply to be closed. See the Equipment Status section of the MM Procedure Start Table.Nitrogen gas in high concentration can cause rapid suffocation.
Locate the nitrogen supply valve to TT/3 before starting any work on the equipment.Note: The location of the nitrogen supply valve to TT/3 is specific for each site.High pressure gas.Close the main carbon dioxide valve to the gas dosing system before any maintenance that requires the carbon dioxide supply to be closed. See the Equipment Status section of the MM Procedure Start Table.Carbon dioxide gas in high concentration can cause rapid suffocation.
Locate the carbon dioxide supply valve to TT/3 before starting any work on the equipment.Note: The location of the carbon dioxide supply valve to TT/3 is specific for each site.Hot Parts in the Package Section
Severe burn hazard.Do not touch the hot parts.Some pipes and other parts are hot during cleaning, sterilisation, heating, and production, specified below.

- Peroxide nozzle
- Peroxide reducer
- Flap heater
- Cleaning box and pipe
- HCCleaning pipe
- UV-lamp
- Air dryer
Equipment for Lifting and Moving Loads
Risk of crushing.Make sure that the capacity of the lifting equipment is adequate and that the equipment itself is in proper working order.The equipment can be heavy and can cause injury and death if it falls.
If lifting tackle must be joined to make up the necessary lengths, make sure that the joints are secure and have the same lifting capacity as the rest of the lifting tackle.Always engage safety clips fitted to lifting hooks to prevent the lifting tackle from slipping off.Use ropes or poles to steady and manoeuvre suspended loads. Do not use hands or feet.Make sure that the route and destination are free from obstacles before moving a suspended load. It must always be possible to quickly and safely lower the load to the floor in an emergency.When depositing loads, keep lifting tackle in place until the stability of the load has been substantiated.Working at Height
This equipment is provided with a means of access to all locations where routine tasks for operation and maintenance need to be carried out.Risk of falling.For any kind of work at height, always ensure that safe means of access is available and used. Where additional safe means of access other than provided with the equipment is required, follow local work at height regulations and guidelines. Use scaffolds or a mobile work platform and a safety harness. Create a safety perimeter around the working area and secure tools or other objects from falling.
Nitrogen
Chemical hazard.Provide good ventilation or local exhaust to prevent accumulation of high concentrations of gas. Oxygen levels in the work area must be monitored to ensure that they do not fall below 19.5%. To ensure enough oxygen concentration in the ambient air, establish an oxygen monitoring system. Consult your local authority regarding regulatory requirements. An oxygen monitoring system is not included in the TetraPak® supply.Risk of death or personal injury. Nitrogen is a nontoxic, odourless, colourless, nonflammable compressed gas, which can cause rapid suffocation at high concentrations. Contact with skin can cause frostbite. Inhalation of cold gas can damage the lungs. Risk of explosion of equipment/pipes due to pressure increase, when nitrogen expands from a fluent to gas state.
Confined Space
Confined space.Assess the hazards, ensure the training of the personnel, ensure appropriate equipment for rescue operations are in place and that personnel know how to use it, and use lockout procedures whenever appropriate.Risk of severe injury or death from entering or working in a confined space in the equipment. Entering or working in a confined space may result in the necessity for a rescue operation, which is time consuming and if not planned and executed properly, can introduce new risks.
- loss of consciousness from the rise in body temperature
- contact with media or chemicals
- unexpected start-up of the equipment
- the nature of the work that is performed
- ingress of gases
Loss of consciousness or reduced mobility that is caused by incident or disease (for example stroke or cardiac arrest) will lead to rescue operations that are time-consuming and require dedicated skills and equipment.To avoid risk of injury, avoid working in a confined space whenever possible. Adopt alternative methods that allow work to be done remotely or from outside the confined space. Work in a different manner that avoids the risk whenever it is reasonably practical to do so.Should work within the confined space be necessary, ensure that local workplace health and safety legislation and site operating procedures for working in confined spaces are complied with.- site operating procedures for confined spaces are missing
- necessary rescue equipment is missing
- all involved personnel have not been trained
Contact the TetraPakGroup, or seek other competent guidance.For TetraPak® personnel and contractors, the Procedure for Confined Spaces and local Standard Operating Procedures apply.Product Pressure
Risk of personal injury.To avoid exposure, make sure that skilled personnel carry out the appropriate action.There is a risk of injury due to equipment parts in motion, or exposure to gas or liquids under pressure, caused by residual pressure in the pressurised equipment if the equipment has not been depressurised fully.
Description
This chapter contains the maintenance procedures for the Automatic Splicing Unit (ASU). The functional description on page Functional Description provides a technical description of the ASU.
Hygiene level XH

Hygiene level AD
Functional Description
The ASU contains two pairs of packaging material reels. One pair for each production line of the TT/3 machine.In each pair, one reel is used for production and the other reel is prepared for splicing.When the Reel in production is empty, the Splicing device moves sideways and automatically splices the Prepared reel .
- Splicing device
- Prepared reel
- Reel
Alarms and Troubleshooting ASU
Overview
| Pos. | Cross reference |
| 1 | 110301091/110311092, SA Oven, Wrong Position |
| 2 | 110301101/110301102, SA Oven Product Side, Wrong Temperature |
| 3 | 110301111/110301112, SA Oven Decor Side, Wrong Temperature |
| 4 | 110301301/110311302, Strip Pre Heater, Wrong Temp (Only valid for HAAD) |
| 5 | 110711211/110711212, Strip Pre-heater, Wrong Position (Only valid for HAAD) |
| 6 | 110701281/110701282, Strip Applicator, Wrong Position |
| 7 | 110301051/110311052, Slack ASU, Out of Range |
| 8 | 110701151/110701152, Splicing Unit, Wrong Position |
| 9 | 110701320/110701210, SA Oven Filter |
110301091/110311092, SA Oven, Wrong Position
DescriptionWhen the machine is stepped up to production, the SA oven moves to a position around the packaging material. The movement is controlled by a pneumatic cylinder, V11M1243 on side 1 and V11M2243 on side 2.Condition for AlarmThe machine is in PRODUCTION step but the sensor V11B1223/V11B2223 does not register that the oven is in product position.- the production stops on the affected machine side. The machine side steps down to MOTOR RUNNING.
- the affected machine side stops cutting new blanks, but fills and finishes all the packages that are currently moving through that side.
- the affected machine side steps down to Tank Filling after ten minutes.
- the unaffected machine side continues to run.
Troubleshooting- Check that the sensor is active when the oven is in production.
- Check that the valve V11K1223/V11K2223 is energized.
110301101/110301102, SA Oven, Product Side, Wrong Temperature
DescriptionThe alarm can be triggered if the machine, in operating temperature, is stepped down below step HEATING, and then up to HEATING or higher again. Step the machine up to HEATING and wait fiveminutes before any actions are taken.Condition for AlarmThe temperature is outside the alarm limits set in the PLC.- the production stops on the affected machine side. The machine side steps down to MOTOR RUNNING.
- the affected machine side stops cutting new blanks, but fills and finishes all the packages that are currently moving through that side.
- the affected machine side steps down to Tank Filling after ten minutes.
- the unaffected machine side continues to run.
Troubleshooting- Check the heater element and change, if necessary. See Procedure Heater - Change Elements.
- Check the air supply.
- Check the thermocouple and change, if necessary. See Procedure Heater - Change Thermocouple.
- Check that the wire is not broken or wrongly connected. The value on the TPOP is 1372 °C if the wire is broken.
- Check that the connection terminal is working. If not, change it.
110301111/110301112, SA Oven, Decor Side, Wrong Temperature
DescriptionThe alarm can be triggered if the machine, in operating temperature, is stepped down below step HEATING, and then up to HEATING or higher again. Step the machine up to HEATING and wait fiveminutes before any actions are taken.Condition for AlarmThe temperature is outside the alarm limits set in the PLC.- the production stops on the affected machine side. The machine side steps down to MOTOR RUNNING.
- the affected machine side stops cutting new blanks, but fills and finishes all the packages that are currently moving through that side.
- the affected machine side steps down to Tank Filling after ten minutes.
- the unaffected machine side continues to run.
Troubleshooting110301301/110311302, Strip Pre-heater, Wrong Temperature
DescriptionThe strip pre-heater is mounted on AD machines. The pre-heater heats up the strip prior to applying it to the packaging material.Condition for AlarmThe temperature is outside the alarm limits set in the PLC.- the production stops on the affected machine side. The machine side steps down to MOTOR RUNNING.
- the affected machine side stops cutting new blanks, but fills and finishes all the packages that are currently moving through that side.
- the affected machine side steps down to Tank Filling after ten minutes.
- the unaffected machine side continues to run.
Troubleshooting- Check the heater element and change, if necessary. See Procedure Strip Pre-heater - Change Heater Element.
- Check the thermocouple and change, if necessary. See Procedure Heater - Change Thermocouple.
- Check that the wire is not broken or wrongly connected. The value on the TPOP is 1372 °C if the wire is broken.
- Check that the connection terminal is working. If not, change it.
110711211/110711212, Strip Pre-heater, Wrong Position
DescriptionThe strip pre-heater is mounted on AD machines. The pre-heater heats up the strip prior to applying it to the packaging material.Condition for AlarmThe machine is in PRE-HEATING step, but the sensor V51B1266/V51B2266 does not register that the pre-heater is in product position.- the production stops on the affected machine side. The machine side steps down to MOTOR RUNNING.
- the affected machine side stops cutting new blanks, but fills and finishes all the packages that are currently moving through that side.
- the affected machine side steps down to Tank Filling after ten minutes.
- the unaffected machine side continues to run.
Troubleshooting- Check the position of the strip pre-heater.
- Check the function of the sensor.
110701281/110701282, Strip Applicator, Wrong Position
DescriptionThe strip applicator applies the strip on the preheated packaging material.Condition for AlarmThe machine is in TANK FILLING step, but the sensor V11B1222/V11B2222 does not register that the strip applicator is in product position.- the production stops on the affected machine side. The machine side steps down to MOTOR RUNNING.
- the affected machine side stops cutting new blanks, but fills and finishes all the packages that are currently moving through that side.
- the affected machine side steps down to Tank Filling after ten minutes.
- the unaffected machine side continues to run.
Troubleshooting- Check the position of the strip applicator.
- Check that the sensor registers the strip applicator.
110301051/110311052, Slack, ASU, Out of Range
DescriptionThe slack motor T10M1214/T10M2214 pulls the packaging material from the reel and through the creasing unit. The slack is monitored by the photocell T10B1205. If the paper web is covering the sensor for more than onesecond, the frequency of the frequency converters T10V1216/T10V2216 is increased by oneHz. If the paper web does not cover the sensor for more than onesecond, the frequency is decreased by oneHz.Condition for AlarmThe slack is out of range for more than 20seconds.- the production stops on the affected machine side. The machine side steps down to MOTOR RUNNING.
- the affected machine side stops cutting new blanks, but fills and finishes all the packages that are currently moving through that side.
- the affected machine side steps down to Tank Filling after ten minutes.
- the unaffected machine side continues to run.
Troubleshooting110701151/110701152, Splicing Unit, Wrong Position
DescriptionThe splice is performed in a sequence. The sequence is as follows:- The paper feed stops.
- Material holder and counter jaw are pressurised.
- Adhesive pulse on TPO Bar to fix web to heating element.
- The knife cuts the packaging material.
- The counter jaw releases.
- The splice unit moves.
- Counter jaw gets pressurized.
- The TPO Bar is energized and the material is sealed together.
- Counter jaw released, release pulse on TPO Bar.
Condition for AlarmThe sensors, that check the end positions of the splice head, are inactive for more than ten seconds.- the production stops on the affected machine side. The machine side steps down to MOTOR RUNNING.
- the affected machine side stops cutting new blanks, but fills and finishes all the packages that are currently moving through that side.
- the affected machine side steps down to Tank Filling after ten minutes.
- the unaffected machine side continues to run.
Troubleshooting- Check that nothing is obstructing the movement.
- The sensors register that the splicing unit is in position. Check that the correct sensor is active:Side 1:1 T10B3203Side 1:2 T10B4203Side 2:1 T10B5203Side 2:2 T10B6203
110701320/110701210 SA Oven Filter
DescriptionThe pressure in the fan system is monitored with three pressure switches located in the electric cabinet in the ASU. When the filter gets clogged, the differential pressure increases. If there is no filter, the differential pressure is too low.Condition for AlarmThe differential pressure is outside the alarm limits for more than fiveseconds.TroubleshootingWeb Guide - Check
| Equipment Status | Program Step step zero |
Note: The Rubber roller of the web guide must be fitted to roll on the printed side of the web.- Check the Rubber roller and the Steel roller for wear and damage. Turn them by hand and check that they rotate smoothly.
- Check the Ball bearing for excessive play. Change the bearings, if necessary.
- Check the distance between the rollers. See Procedure Web Guide - Set on page Web Guide - Set.

- Rubber roller
- Steel roller
- Ball bearing
Pressure Roller - Set
| Equipment Status | Program Step step zero |
To achieve the correct tension of the Spring do the following:- Loosen the Screw.
- With packaging material between the pressure roller and the bending roller, set the Lever to the distance A. Tighten the Screw.

A = 140 ±1 mm
- Lever
- Screw
- Spring
Pressure Roller - Change
| Equipment Status | Program Step STEP ZERO |
| Consumables | Anti-seize: TP No. 344417-0000 or 344418-0000 |
- Remove the Spring.
- Remove the Pin and the pressure roller assembly.Note: When assembling, apply anti-seize to the rod ends.

- Spring
- Pin
- Remove the Retaining ring, Retaining ring, and the Pin.
- Remove the Nut and the Screw.
- Remove the Retaining ring.
- Change the Bearing.
- Check the Bearing and change, if necessary.
- Assemble in the reverse order.
- Set the pressure roller. See Procedure Pressure Roller - Set on page Pressure Roller - Set.

- Pin
- Retaining ring
- Retaining ring
- Bearing
- Nut
- Screw
- Retaining ring
- Bearing
Creasing Unit - Check Rollers and Bearings
| Equipment Status | Program Step step zero |
When performing checks from outside the ASU, make sure to use the ladder belonging to the machine.- Check Creasing roller and Creasing roller for damage.
- Check that the ball bearings (see arrows) rotate freely and do not cause abnormal noise when the creasing rollers revolve.
- If required, change the bearings. See Procedure Creasing Unit - Change Bearings on page Creasing Unit - Change Bearings.

- Creasing roller
- Creasing roller
Creasing Unit - Check Spring and Creasing Roller
| Equipment Status | Program Step step zero |
- Remove the Web guide. See Procedure Creasing Unit - Remove Web Guide.

- Web guide
- Check the compression of the Spring washer by checking the distance B.Note: The rollers must be held steadily to prevent from turning while measuring.
- Fix the Female creasing roller and then turn the Male creasing roller until the distance A between the Male creasing roller and Female creasing roller is maximised. Fix the Male creasing roller and turn the Female creasing roller until the distance A between the rollers is maximised.
- Fix both rollers.
- Check the distance A between the rollers at both ends of the rollers.
| Not valid for: packaging material with Al-foilNot valid for: packaging material with bleached board |
| Distance | Base 370mN | Base 475mN | Midi | Mini STD, Mini V | Micro |
| A (mm) | 0.85 ±0.02 | 0.95 ±0.02 | 0.80 ±0.02 | 0.75 ±0.02 | 0.70 ±0.02 |
| B (mm) | 15.5 ±0.5 | 15.5 ±0.5 | 15.5 ±0.5 | 15.5 ±0.5 | 15.5 ±0.5 |
| Valid for: packaging material with Al-foil |
| Distance | Midi | MidiValid for: ASCM with Klabin board | Mini STD, Mini V |
| A (mm) | 0.95 ±0.02 | 0.90 ±0.02 | 0.85 ±0.02 |
| B (mm) | 15.5 ±0.5 | 15.5 ±0.5 | 15.5 ±0.5 |
| Valid for: packaging material with bleached board and without Al-foil |
| Distance | Base | Midi/Mini STD, Mini V |
| A (mm) | 0.95 ±0.02 | 0.90 ±0.02 |
| B (mm) | 15.5 ±0.5 | 15.5 ±0.5 |

- Male creasing roller
- Female creasing roller
- Spring washer
Creasing Unit - Set Centering
| Equipment Status | Program Step step zero |
| Consumables | Plastic film TP No.1355671-0000 |
- Loosen the Socket screw. See illustration on next page.
- Make sure the male creasing rollers are running in their grooves according to the illustration below.
- Pull a piece of packaging material for base between the creasing rollers.Note: The creasing rollers must roll forward on fresh packaging material. Previously made creases may not be inserted.
- Tighten the Socket screw lightly and crosswise. See illustration on next page.
- Pull out the piece of packaging material.
- Check the centring of the creasing rollers. See Procedure Creasing Unit - Check Centering on page Creasing Unit - Check Centering.If the result is not OK, continue on item Reference to Reference. See next page.
- If the creasing roller needs to be adjusted to the right, loosen the Socket screw in the setting ring on the right side of the creasing roller. If the creasing roller needs to be adjusted to the left, loosen the Socket screw in the setting ring on the left side of the creasing roller.
- Insert a Feeler gauge, of the thickness equal to the distance the male Creasing roller that needs to be moved, between the creasing roller and the unloosened Setting ring.
- Tighten the Socket screw and loosen the opposite socket screw.
- Remove the Feeler gauge.
- Move the Setting ring toward the creasing roller and tighten the socket screw.
- Check the centring of the creasing rollers. See Procedure Creasing Unit - Check Centering on page Creasing Unit - Check Centering.
- If necessary, repeat the item Reference to Reference for the other creasing roller.
- Make a note of the date, machine, line, and your sign on the last piece of plastic film you have used for checking. Keep the plastic film in an envelope placed in the electric cabinet.

- Socket screw
- Feeler gauge
- Creasing roller
- Setting ring
Creasing Unit - Remove Web Guide
| Equipment Status | Program Step STEP ZERO |
| Consumables | Anti-seize: TP No. 344417-0000 or 344418-0000 |
- Remove the Wheel and the Nut.
- Remove the Screw and pull out the Rod while removing the Web guide.Note: Apply anti-seize on the end of the Rod during assembly.
- Remove the Screw and the Plate.

- Wheel
- Nut
- Screw
- Rod
- Web guide
- Screw
- Plate
Creasing Unit - Set Female Crease Roller Distance
| Equipment Status | Program Step STEP ZERO |
| Special Equipment | Support Roller, TP No. 3383226 |
The separated crease roller was introduced from machine 63202/20089. It is also included in OK Mini 330 TT/3 2000.The original distance, between the sleeve forming creases, is 87mm for the Mini format. This corresponds to 0pc of Shim in the Female crease roller. Each shim is 0.05mm. Adding shim will increase the sleeve size.Note: This setting requires knowledge of the sleeve forming function.
- Shim
- Female crease roller
- Remove the web guide and the plate. See Procedure Creasing Unit - Remove Web Guide.
- Remove the Nut and the spring washers.Note: Be careful not to lose the Shim.
- Lift out the Male crease roller.

- Nut
- Shim
- Male crease roller
- Remove the Screw and Screw.
- Remove the Bracket, the Shaft, and the Bushing.
- Lift out the Female crease roller.

- Female crease roller
- Screw
- Screw
- Bracket
- Shaft
- Bushing
- Place the Female crease roller in the Support roller, TPNo.3383226.
- Loosen the Screw and separate the Female crease roller.
- Add/Remove Shim.Note: It is recommended to make small distance changes, like 0.1mm (two Shim equals 0.1mm).
- Assemble in the reverse order. Tighten the Screw alternately to the torque 8.4+/-0.3N. Use a torque wrench.
- Check the centring of the creasing unit. See Procedure Creasing Unit - Check Centering.
- Check the distance between the female and male crease rollers. See Procedure Creasing Unit - Check Spring and Creasing Roller.

- Shim
- Female crease roller
- Support roller
- Screw
Splicing Device Bracket - Check Cylinders
| Equipment Status | Program Step AIR ON |
- Activate the pneumatic valves T10K1223 for side 1 and T10K2223 for side 2.
- Check the Cylinder and the Pneumatic hose for leaks.
- Check that the Counter jaw has moved to its end position.
- Deactivate the pneumatic valves.
- Check that the Counter jaw fully withdraws.
- Pneumatic hose
- Cylinder
- Counter jaw
Splicing Device Bracket - Set Cutting Template
| Equipment Status | Program Step air on |
- Make splices with the splicing device in the lines 1:1, 1:2, 2:1, and 2:2 positions.
- Adjust the Cutting template sideways with the Screw, see illustration on next page, until the splices show no offset at the left hand side of the web (maximum A). The heating temperature must not be too high (causing charred sealing surfaces).
- Tear apart the splice and check that the sealing surfaces are 100% covered with paper fibres. See Procedure Cutting Unit - Check Sealing Rail and Splice Quality on page Cutting Unit - Check Sealing Rail and Splice Quality.
Splicing Device Bracket - Change Cylinders/Counter Jaw
| Equipment Status | Program Step STEP ZERO |
- Move the splicing device fully to its right hand position for side 1 or fully to its left hand position for side 2.
- Measure the distance A from the ball bushing Bracket of the splicing device to the Frame of the ASU. Note the distance.
- Remove the Paper guide and disconnect the Pneumatic hose.
- Remove the Bracket for the Cylinder.
- Remove the Screw and the Cylinder.
- Bracket
- Frame
- Paper guide
- Pneumatic hose
- Bracket
- Cylinder
- Cylinder
- Screw
- Pull out the Counter jaw and the Spring.
- Change the Counter jaw.
- Put in the new counter jaw and the Spring.
- Put back the Cylinder.
- Put back the Bracket. Before fastening the bracket, move the splicing device to the distance A and the Cylinder to their corresponding end positions.
- Connect the pneumatic hoses and put back the paper guides.
- Check the cylinder movements. See section Web Guide on page Web Guide.
- Check that the Splicing device moves smoothly along the Rod.
- Check the splices of the packaging material.

- Counter jaw
- Spring
- Splicing device
- Rod
Splicing Device Bracket - Change Bearings
| Equipment Status | Program Step step zero |
- Remove the Screw, Screw, and the Bracket.
- Pull out the plastic Shaft.
- Remove the Retaining ring, the Screw, and the Motor.
- Remove the Key and the Axle.
- Lift out the Roller.
- Remove the Screw.
- Change the Bearing.

- Screw
- Screw
- Bracket
- Shaft
- Retaining ring
- Screw
- Motor
- Key
- Axle
- Roller
- Screw
- Bearing
- Remove the Screw and pull out the plastic Shaft.
- Lift out the Roller.
- Remove and change the Bearing.
- Repeat items h) to j) for the Roller.
- Assemble in the reverse order.

- Screw
- Shaft
- Roller
- Bearing
- Roller
Splicing Device Bracket - Check Motor for Oil Leakage
| Equipment Status | Air must be turn ON.
|
Valid for Motors Mounted Vertically
- Check for oil leakage under the fan cover of the Motor. If there are oil drops under the fan cover, dry and remove oil drops.

- Motor
Valid for Motors Mounted Horizontally
- Check for oil leakage under the Motor on the Guard plate. If there are oil drops, dry and remove the oil drops.

- Guard plate
- Motor
Splicing Device Bracket - Change Motor
| Equipment Status | Power must be turn OFF.
|
Valid for Motors Mounted Vertically
- Remove the Screw, the Screw, and the Bracket.
- Pull out the plastic Shaft.
- Remove the Retaining ring, the Screw, and the Motor.
- Change the Motor and assemble in the reverse order.
- If oil leaks are found under the motor fan cover, remove the oil drops.

- Screw
- Screw
- Bracket
- Shaft
- Retaining ring
- Screw
- Motor
Valid for Motors Mounted Horizontally
- Remove the Screw, the Screw, and the Bracket.
- Pull out the plastic Shaft.

- Screw
- Screw
- Bracket
- Shaft
- Remove the Screw to remove the Guard plate.
- Remove the Retaining ring.
- Remove the four Screw from the Flange, then remove the Motor together with the Flange.
- Move the Motor to a workbench and disassemble the Flange from the Motor.
- Change the Motor and assemble in the reverse order.

- Screw
- Guard plate
- Retaining ring
- Screw
- Flange
- Motor
Cutting Unit - Check Cylinders and Knife Holder
| Equipment Status | Program Step air on |
| Consumables | Thread locker: TP No. 351532-0000 |
- Check the distance A. This is the basic setting of the Setting screw.If necessary, apply thread locker on the Setting screw and set the distance A.
- Check the Cylinder and the Pneumatic hose for leaks.
Risk of cutting.Be careful when working near them.The knives in the machine are sharp.
Check that the Knife and the Knife holder move smoothly. If necessary, use the Screw to adjust.
A = 20 ±0.5 mm
- Cylinder
- Setting screw
- Pneumatic hose
- Knife holder
- Knife
- Screw
Risk of crushing.Be careful when working near the moving parts.Parts can move when the pneumatic valves are activated.
Activate the pneumatic valves T10K1219 for side 1 and T10K2219 for side 2. Check the distance B between the Knife and the bracket with the Knife in end position.- Deactivate the pneumatic valves. Check that the Knife holder fully withdraws by checking the distance C, between the Knife and the bracket.

B = 5 ±1 mm
C = 1 +1/-0 mm
- Knife holder
- Knife
Cutting Unit - Check Sealing Rail and Splice Quality
| Equipment Status | Program Step step zero |
Check a single splice seal. Take a piece of packaging material with a splice from a previous production. - Check that the heating temperature has not been too high, which may result in the sealing surface getting burnt.
- Tear open the splice and check that the sealing zones of both pieces of packaging material are completely covered with paper fibres.
Corrections
- If burnt sealing zones occur, decrease the time of the sealing pulse.
- If the sealing zones are not completely covered with paper fibres, increase the time of the sealing pulse.
Cutting Unit - Change Sealing Rail
| Equipment Status | Power must be turn OFF.
|
Hazardous voltage.The main power supply disconnector must be switched off and secured with a lock before starting any work on the electrical equipment.Will shock, burn, or cause death.
- Remove the Nut and the Cutting unit.
- Loosen the Cable gland to allow to pull the Cable through.
- Remove the Screw.
- Pull out the cables and change the Sealing rail.
Risk of damage to the equipment.Do
not tighten the
Screw too much.Too high torque can damage the insulation bushing.
Push back the cables and reconnect the cables to the sealing rail. It is important that the Insulation bushing are fitted between the heads of the Screw and the cables. Make sure that the insulation bushings are not damaged. If the bushings are damaged, they must be changed.- Assemble in the reverse order.

- Cutting unit
- Nut
- Cable gland
- Cable
- Screw
- Sealing rail
- Insulation bushing
Material Holder - Change Holding Cylinders
| Equipment Status | Program Step step zero |
- Disconnect the Pneumatic hose.
- Remove the Screw and the Cylinder.
- Set the length of the Pin so that they hit the Wall when the distance is A.
- Assemble in the reverse order.

A = 3 ±0.5 mm
- Pneumatic hose
- Cylinder
- Screw
- Pin
- Wall
Material Holder - Change Moving Cylinders
| Equipment Status | Program Step step zero |
- Move the splicing device fully to its right hand position for side 1 and fully to its left hand position for side 2.
- Measure the distance A from the Ball bushing bracket of the splicing device to the Frame of the ASU.

- Ball bushing bracket
- Frame
- Disconnect the pneumatic hoses from the Pneumatic hose connection.
- Remove the Screw for the Bracket.
- Remove the two upper Screw from both Bracket.
- Loosen the two lower Screw from one of the Bracket.
- Lift out the Cylinder.
- Remove the Bracket with the Pin from the cylinder and change the cylinder.
- Install the new cylinder without tightening the Screw. Note: The two oval holes in the Bracket are to be fitted to the Cylinder.

- Cylinder
- Pneumatic hose connection
- Screw
- Bracket
- Screw
- Bracket
- Pin
- Put back the Screw for the Bracket. Before tightening the Screw, move the splicing device to the distance A (see previous page), and the cylinder to its corresponding end position.
- Tighten the Screw at the end of the Cylinder.
- Move the splicing device to its other end position. Tighten the Screw at the other end of the Cylinder.
- Check the movements of the splicing device.
- Check for air leaks.

- Cylinder
- Screw
- Bracket
- Screw
Functional Description
The functions of the strip applicator unit are to heat up one edge of the packaging material, pre-heat the strip (only valid for hygiene level AD), seal the strip to the heated edge, and automatically or manually splice in a new reel of strip when a reel is finished.Strip Applicator House - Set Bending Rollers
| Equipment Status | Program Step step zero |
| Special Equipment | Template TP No. 2712575-0001 (Base) Template TP No. 2712575-0002 (Midi) Template TP No. 2712575-0003 (Mini) Template TP No. 2712575-0004 (Micro) |
Note: If a template is not available, set the rollers according to the distances A and B in the table below.- Place the Bending roller as illustrated on next page.
- Set the Flange and make sure it is aligned with the end of the roller.
- Tighten the screw in the Flange.

- Bending roller
- Flange
- Set the Template and the Flange according to the table below. Maximum allowed difference in parallelity between Flange and Flange is 0.2 mm.
| Bottom Size | Template TP No. | Distance A (mm) | Distance B (mm) |
| Base | 2712575-0001 | 266.5 | 278.5 |
| Midi | 2712575-0002 | 215 | 227 |
| Mini | 2712575-0003 | 181 | 193 |
| Micro | 2712575-0004 | 139 | 151 |
- Tighten the screws in Flange.
- Remove the Template.
- Repeat the setting for the Bending roller.

- Flange
- Template
- Bending roller
Strip Applicator House - Set Web Guide
| Equipment Status | Program Step step zero |
- Set the Web guide in line with the edge of the material web, by using a Ruler, according to the illustration below.
- Set the distance A between the Ruler and the Flange, with the Stop screw.
- Check during production that the material web does not touch the Flange.

A = 0.7 ±0.2 mm
- Ruler
- Flange
- Web guide
- Stop screw
Strip Applicator
For the TT/3 filling machine, there are two versions of the Strip Applicator.
Strip Applicator Version 1

Strip Applicator Version 2
For a Strip Applicator, there are two versions of the outer roller Wheel. The appearance of the Wheel depends on the hygiene level of the machine and the type of packaging material.
Hygiene level AD

Hygiene level XH
Strip Applicator Version 1 - Check Alignment
| Equipment Status | Program Step step zero |
Burn hazard.Allow the rollers to cool down before starting any work on the strip applicator.The rollers can be hot.
- Check the distances A, B, and C.
- Check that all the rollers are in line. The distance D is the allowed deviation from the ideal line for the rollers. If the rollers are not in line, see Procedure Strip Applicator House - Set Bending Rollers on page Strip Applicator House - Set Bending Rollers.

A (mm) = 38.1 ±0.1
B (mm) = 17 ±0.1
C (mm) = 18 ±0.1
D (mm) = 0 ±0.3
Strip Applicator Version 1 - Check Splice and Strip Sealing
| Equipment Status | Program Step air on |
Check Splice
- Insert a double-folded strip in the heating device.
- Make a splice by pushing the button for manual splicing.
- Check that the offset of the Strip does not exceed the distance A, as illustrated.
- Check the strength in the splice by pulling the ends of the spliced Strip. Grip a strip, with the distance B, between the hands. Tension the Strip slightly. Without tearing apart the splice of the strip, a lengthening of the distance C will be possible.
- Check that the seal is cut from the old Strip by the thin heating wire and spliced by the thick heating band. Adjust to set the block and the pad parallel. See Procedure Heating Device - Set Position on page Heating Device - Set Position.
- If the spliced Strip detaches, increase the temperature. If the splice breaks, decrease the temperature.

A (mm) = 0 +0.5/-0
B (mm) = 200 ±5
C (mm) = 50 ±5
- Strip
Check Strip Sealing
- Bring a piece of packaging material, with the strip sealed to the packaging material.
- Tear off the Strip perpendicular to the Packaging material. The inner as well as the outer plastic coating of the Packaging material is torn off from the Packaging material. Check that the Strip is attached properly and that no blocking occurred.Note: The end of the Strip is easy to grip if the Corner of the Packaging material is torn off.
- Check that the width of the Heating zone is distance D.
- Check that the overlap of the Strip is distance E.
- If the sealing between web and strip is not good enough, either oven temperature or oven position (Heater - Set Cylinder on page Heater - Set Cylinder) can be changed. Also check that the Heating zone is not overheated.

D (mm) = 8 ±2
E (mm) = 3.5 ±1.0
- Strip
- Corner
- Packaging material
- Heating zone
Strip Applicator Version 1 - Set
| Equipment Status | Program Step step zero |
- The Plumb line must only touch the lower Roller.
- Set the Casting by loosening the Nut and turning the Screw.
- When the Casting is vertically aligned, tighten the Nut.

- Plumb line
- Roller
- Casting
- Nut
- Screw
Check
- Measure the distance A.
- Measure the distance B and calculate A-B = A1.
- Measure the distance C.
- Measure the distance D and calculate C-D = A2.
- The difference between the distances A1 and A2 must not exceed 0.3 mm. If the difference exceeds 0.3 mm, continue to Set.
Set
- To set the Strip applicator, put a Shim between the strip applicator cast and the Bracket. Perform this setting only if really necessary.
- Set the Roller between the shaft of the roller and the Bracket.
- Set the Rotation guard with shim between the shaft of the rotation guard and the Plate.

- Strip applicator
- Shim
- Bracket
- Roller
- Bracket
- Rotation guard
- Plate
- Template
Strip Applicator Version 1 - Clean
| Equipment Status | Program Step step zero |
Burn hazard.Allow the heater unit to cool down before starting any work on the strip applicator.The heater unit can be hot.
- Remove the Nut, the Spring, the Wheel, and the Strip sealing wheel.
- Clean the Wheel and the Strip sealing wheel.

- Nut
- Spring
- Wheel
- Strip sealing wheel
- Assemble the Wheel, the Strip sealing wheel, the Spring, and the Nut in the reverse order.
- Check that the levers and wheel easily spring back by:
- pressing the levers, see arrows
- pulling the Wheel
- If the levers and wheel do not spring back, remove the parts, clean, and assemble in the reverse order.
- If the wheels are worn, damaged, or do not spin smoothly, change the wheels.

- Wing nut
- Spring
- Wheel
- Strip sealing wheel
- Roller
- Roller
Strip Applicator Version 1 - Set Alignment
| Equipment Status | Program Step step zero |
- Check that the Plumb line is touching the side of the Wheel. If necessary, add or remove Shim to adjust the strip applicator.

- Plumb line
- Wheel
- Shim
- Check that the Paper support opposite to the Wheel is aligned and is touching the Plumb line.
- Set the gap between the paper supports. See Procedure Paper Support - Set.

- Plumb line
- Wheel
- Paper support
Strip Applicator Version 2 - Check Alignment
| Equipment Status | Program Step step zero |
Burn hazard.Allow the rollers to cool down before starting any work on the strip applicator.The rollers can be hot.
- Check the distances A, B, and C.
- Check that all the rollers are in line. The distance D is the allowed deviation from the ideal line for the rollers. If the rollers are not in line, see Procedure Strip Applicator House - Set Bending Rollers on page Strip Applicator House - Set Bending Rollers.

A (mm) = 38.1 ±0.1
B (mm) = 17 ±0.1
C (mm) = 18 ±0.1
D (mm) = 0 ±0.3
Strip Applicator Version 2 - Check Splice and Strip Sealing
| Equipment Status | Program Step air on |
Check Splice
- Insert a double-folded strip in the heating device.
- Make a splice by pushing the button for manual splicing.
- Check that the offset of the Strip does not exceed the distance A, as illustrated.
- Check the strength in the splice by pulling the ends of the spliced Strip. Grip a strip, with the distance B, between the hands. Tension the Strip slightly. Without tearing apart the splice of the strip, a lengthening of the distance C will be possible.
- Check that the seal is cut from the old Strip by the thin heating wire and spliced by the thick heating band. Adjust to set the block and the pad parallel. See Procedure Heating Device - Set Position on page Heating Device - Set Position.
- If the spliced Strip detaches, increase the temperature. If the splice breaks, decrease the temperature.

A (mm) = 0 +0.5/-0
B (mm) = 200 ±5
C (mm) = 50 ±5
- Strip
Check Strip Sealing
- Bring a piece of packaging material, with the strip sealed to the packaging material.
- Tear off the Strip perpendicular to the Packaging material. The inner as well as the outer plastic coating of the Packaging material is torn off from the Packaging material. Check that the Strip is attached properly and that no blocking occurs.Note: The end of the Strip is easy to grip if the Corner of the Packaging material is torn off.
- Check that the width of the Heating zone is distance D.
- Check that the overlap of the Strip is distance E.
- If the sealing between web and strip is not good enough, either oven temperature or oven position (Heater - Set Cylinder on page Heater - Set Cylinder) can be changed. Also check that the Heating zone is not overheated.

D (mm) = 8 ±2
E (mm) = 3.5 ±1.0
- Strip
- Corner
- Packaging material
- Heating zone
Strip Applicator Version 2 - Set
| Equipment Status | Program Step step zero |
- The Plumb line must only touch the lower Roller.
- Set the Casting by loosening the Nut and turning the Screw.
- When the Casting is vertically aligned, tighten the Nut.

- Plumb line
- Roller
- Casting
- Nut
- Screw
Check
- Measure the distance A.
- Measure the distance B and calculate A-B = A1.
- Measure the distance C.
- Measure the distance D and calculate C-D = A2.
- The difference between the distances A1 and A2 must not exceed 0.3 mm. If the difference exceeds 0.3 mm, continue to Set.
Set
- To set the Strip applicator, put a Shim between the strip applicator cast and the Bracket. Perform this setting only if necessary.
- Set the Roller between the shaft of the roller and the Bracket.
- Set the Rotation guard with shim between the shaft of the rotation guard and the Plate.

- Strip applicator
- Shim
- Bracket
- Roller
- Bracket
- Rotation guard
- Plate
- Template
Strip Applicator Version 2 - Clean
| Equipment Status | Program Step step zero |
Burn hazard.Allow the heater unit to cool down before starting any work on the strip applicator.The heater unit can be hot.
- Remove the Nut, the Spring, the Wheel, and the Strip sealing wheel.
- Clean the Wheel and the Strip sealing wheel.

- Nut
- Spring
- Wheel
- Strip sealing wheel
- Assemble the Wheel, the Strip sealing wheel, the Spring, and the Nut in the reverse order.
- Check that the levers and wheel easily spring back by:
- pressing the levers, see arrows
- pulling the Wheel
- If the levers and the wheel do not spring back easily, remove the parts, clean, and assemble in the reverse order.
- If the wheels are worn, damaged, or do not spin smoothly, change the wheels.

- Nut
- Spring
- Wheel
- Strip sealing wheel
- Roller
Strip Applicator Version 2 - Set Alignment
| Equipment Status | Program Step step zero |
Note: The outer part of the wheel is different for AD and XH variants.
Hygiene level AD

Hygiene level XH
- Check that the Plumb line is touching the side of the Wheel. If necessary, add or remove Shim to adjust the position of the strip applicator.

Variant HAAD is shown.
- Plumb line
- Wheel
- Shim
- Check that the Paper support, opposite to the Wheel, is aligned and touching the Plumb line.
- Set the gap between the paper supports. See Procedure Paper Support - Set.

- Plumb line
- Wheel
- Paper support
Pressure Roller - Check
| Equipment Status | Program Step step zero |
Risk of damage to the equipment.Do
not fold the
Pressure roller more than necessary to open the gap between the two rollers.If the rollers are separated to much, the
Spring can be damaged.
- Check that the Pressure roller and the Counter roller are intact and rotate freely.
- Check that the bearing play does not exceed 0.5 mm.
- Check that the Teflon sleeves of the rollers are intact.
- Check the function of the Spring.

- Pressure roller
- Counter roller
- Spring
Pressure Roller - Change Rollers and Bearings
| Equipment Status | Program Step STEP ZERO |
- Remove the Nut and change the Washer, the Bearing, and the Pressure roller.
- Remove the Screw and change the Washer, the Bearing, and the Counter roller.
- Assemble in the reverse order.

- Nut
- Washer
- Bearing
- Pressure roller
- Screw
- Washer
- Bearing
- Counter roller
Web Guide - Set
| Equipment Status | Program Step STEP ZERO |
| Special Equipment | Plummet Ruler TP No.1147543-0000 |
- Set the distances A between the Roller and the Web guide. Use the Fastening screw of the web guide when setting.
- Set the vertical part of the Web guide by using a plummet line or a steel ruler. Use the Fastening screw when setting.

A (mm) = 1.5 +0.5/-0
- Roller
- Web guide
- Fastening screw
- Place the ruler at side 1.Note: If the ruler 1147543 is not available for the setting procedure, add 20 mm to the A and B distances.
- Set the distance B between the outer side of the web guide and the machined surface on the machine body.
- The distance are to be set to the outside of the web guide. Use the fastening screws of the web guide when setting.
- Set the web guide in line with the flanges of the bending rollers.
- Place the ruler at side 2.
- Set the distance B. The distances are to be set to the inside of the web guide. Use the fastening screws of the web guide when setting.
| Distance | Base | Midi | Mini | Micro |
| A (mm) | 503 ±1 | 534 ±1 | 551 ±1 | 572 ±1 |
| B (mm) | 158 ±1 | 137 ±1 | 120 ±1 | 99 ±1 |

Side 1 Side 2
- Ruler
- Paper guide
Heater - Check Cooling Bodies
| Equipment Status | Program Step HEATING |
Burn hazard.Be careful when working near the hot surfaces.The heater unit can be hot.
- Check the Hose connection for leaks.
- Check the Cooling body for damage and plastic deposits. Clean the nozzles, if required. See Procedure Heater - Clean Nozzles on page Heater - Clean Nozzles.

- Hose connection
- Cooling body
Heater - Check Link Arms
| Equipment Status | Program Step STEP ZERO |
Burn hazard.Allow the heater unit to cool down before starting any work on it.The heater unit can be hot.
- Check that there is no excessive play in the suspension of the heater unit.
- If required, change the six Ball bearing.

- Ball bearing
Heater - Set Cooling Bodies
| Equipment Status | Program Step STEP ZERO |
| Special Equipment | Template Oven TP No. 2523707-0000 |
Burn hazard.Allow the heater unit to cool down before starting any work on it.The heater unit can be hot.
Basic Set
- Loosen the Nut and the Nut.
- Centre the two Cooling body over the Slot in the heater unit.
- Use the Template to set the distance A between the Cooling body.
- The template is two millimetres thick, this due to that the cooling bodies are set in a non heated condition.
- Tighten the Nut.
- Put the Stop lug in close contact with the Cooling body.
- Tighten the Nut.
Final Set
- Step the machine up to heating and wait until the heater has reached its working temperature.
- Check the distance A by using a 1.5 mm feeler gauge. If necessary, set the distance A.Note: Check with the feeler gauge at several places along the cooling bodies, this due to that the Cooling body twist when they are heated.

A (mm) = 1.5 +0.3/-0 (in warm condition)
- Slot
- Nut
- Nut
- Cooling body
- Stop lug
- Template
Heater - Set Cylinder
| Equipment Status | Program Step AIR ON |
Burn hazard.Allow the heater unit to cool down before starting any work on it.The heater unit can be hot.
Basic Setting
Set the length of the Spring, including its plastic bushings to distance D, by adjusting the cylinder rod in its Bracket.Setting of Position
The calculation to get the correct position for the packaging material in the Heating nozzle is A - B = C.- Measure the distance A, without Packaging material.

C (mm) = 15 ±0.5
D (mm) = 154 ±1
- Spring
- Bracket
- Heating nozzle
- Packaging material
- With Packaging material and cylinder activated (SA-oven in production position), make a mark at the Packaging material outside the Cooling body, roll down and measure the distance B. Calculate the distance C.
- Set the distance C by adjusting the Setting screw. If it is impossible to reach the required distance C, shorten the distance D at theBracket.
- Check that the distance B is parallel at the bottom respectively the top of the SA-oven. If necessary, adjust at the Screw.

C (mm) = 15 ±0.5
D (mm) = 154 ±1
- Bracket
- Packaging material
- Cooling body
- Setting screw
- Screw
Heater - Clean Nozzles
| Equipment Status | Program Step STEP ZERO |
Burn hazard.Allow the heater unit to cool down before starting any work on it.The heater unit can be hot.
- Check that the Cooling body is against the Stop lug.
- Remove the Nut.
- Remove the Cooling body.Note: To clean the Nozzle, only one Cooling body needs to be removed.
Risk of damage to the equipment.Use a non-metal tool, for example a tool made of wood or plastic, when cleaning the
Nozzle.Metallic tools can damage the
Nozzle.
Clean the Nozzle.- Put back the Cooling body and push it against the Stop lug.
- Tighten the Nut.

- Nut
- Cooling body
- Nozzle
- Stop lug
Heater - Change Elements
| Equipment Status | Power must be turn OFF.
|
Hazardous voltage. The main power supply disconnector must be switched off and secured with a lock before starting any work on the heater.Will shock, burn, or cause death.
Burn hazard.Allow the heater unit to cool down before starting any work on it.The heater unit can be hot.
- Disconnect the cables in box V11X1229 for side 1 and in box V11X2229 for side 2.
- Disconnect the air hose from the Pipe bend.Note: The element will follow the pipe bend up, by the cables.
- Loosen the Screw and remove the Pipe bend.

- Screw
- Pipe bend
- Loosen the earth cable (inside the pipe bend).
- Loosen the nut of the Cable gland to allow the cables to slide through.
- Change the Element.
- Assemble in the reverse order. Note: Fit the Gasket to the two Pin in order to secure the gasket during assembling.

- Cable gland
- Gasket
- Gasket
- Element
- Pin
Heater - Change Thermocouple
| Equipment Status | Power must be turn OFF.
|
| Consumables | Anti-seize: TP No. 344418-0000 |
Hazardous voltage. The main power supply disconnector must be switched off and secured with a lock before beginning any work on the heater.Will shock, burn, or cause death.
Burn hazard.Allow the heater unit to cool down before beginning any work on it.The heater unit can be hot.
Change of the Upper Thermocouple
- Disconnect the Cable from the Thermocouple.
- Remove the Nut and the Cooling body.
- Remove the Nut and the Thermocouple.
- Make a mark on the new Thermocouple outside the Nut (see arrow), so that the distance A is maintained during fitting.Note: Use a permanent marker.
- Assemble the Thermocouple in the oven, and keep an eye on the mark so that the distance A is not changed.
- Change the thermocouple and the cone under the Nut.
- Apply anti-seize on the Nut.
- Connect the Cable.
- Assemble the Cooling body.

A (mm) = 90
- Cable
- Thermocouple
- Nut
- Nut
- Cooling body
Basic Settings Strip Applicator
Cells containing hyphen (-) refers to a setting when the configuration exists, but no value is set.Cells with grey background refer to a setting in which the configuration does not exist.Italic text refers to a setting that has not been verified, but are based on verified settings from similar configurations.Designations /ml, /ml-H, /ml-H+, /pbl, /jl, /jl MF, /aqk and /lk indicate different packaging material specifications.The letters P and D indicate settings for temperature (°C) valid for the Product side respectively for the Decor side.| Valid for: CLC/C Duplex board |
| Bottom format | Board stiffness (mN) | Volume (ml) | Blanks length (mm) | Temperature (°C) |
| /ml | /ml-H | /ml-H+ | /pbl | /jl | /jl MF | /aqk | /lk | | | |
| P | D | P | D | P | D | P | D | P | D | P | D | P | D | P | D |
| Base | 475 | 1000 | 245 | | | 260 | 300 | - | - | - | - | | | | | | | | |
| Base | 475 | 750 | 210 | | | 260 | 270 | - | - | - | - | | | | | | | | |
| Base | 370 | 1000 | 245 | 230 | 270 | 240 | 270 | - | - | 250 | 280 | | | | | | | | |
| Base | 370 | 750 | 210 | 220 | 260 | - | - | - | - | 230 | 270 | | | | | | | | |
| Base | 370 | 500 | 155 | 210 | 250 | - | - | - | - | 210 | 260 | | | | | | | | |
| Midi | 260 | 500 | 200 | 230 | 250 | - | - | - | - | - | - | - | - | | | 240 | 300 | - | - |
| Midi | 260 | 400 | 173.3 | 220 | 250 | - | - | - | - | 240 | 290 | | | | | | | | |
| Midi | 260 | 330 | 150 | 200 | 230 | - | - | - | - | - | - | | | | | 250 | 290 | | |
| Midi | 260 | 300 | 140 | | | | | | | | | 220 | 300 | | | | | | |
| Midi | 260 | 250 | 130 | 190 | 230 | 210 | 280 | 210 | 280 | - | - | | | | | | | | |
| Midi | 260 | 200 | 108 | - | - | - | - | - | - | 240 | 270 | | | | | | | | |
| MiniV | 260 | 330 | 175 | 220 | 240 | - | - | - | - | 240 | 290 | | | | | | | | |
| MiniV | 260 | 250 | 142.5 | 200 | 230 | 240 | 280 | 240 | 280 | - | - | 250 | 290 | | | | | | |
| MiniV | 260 | 200 | 125 | 190 | 230 | 210 | 280 | 210 | 280 | - | - | 240 | 280 | | | | | | |
| Mini | 260 | 330 | 180 | 220 | 250 | - | - | - | - | 240 | 290 | | | | | | | | |
| Mini | 260 | 250 | 147.5 | 200 | 230 | 240 | 250 | 240 | 250 | - | - | 250 | 290 | | | | | 230 | 270 |
| Mini | 260 | 200 | 130 | 190 | 230 | - | - | - | - | - | - | 240 | 280 | 210(1) | 280(1) | | | | |
| Mini | 260 | 150 | 108 | | | | | | | 240 | 270 | | | | | | | | |
| Micro | 150 | 100 | 108 | | | | | | | 240 | 270 | | | | | | | | |
| (1) 150 mN board stiffness |
| Valid for: CLC/C Bleached board |
| Bottom format | Board stiffness (mN) | Volume (ml) | Blanks length (mm) | Temperature (°C) |
| /ml | /ml-H | /ml-H+ | /pbl | | | |
| P | D | P | D | P | D | P | D |
| Base | 475 | 1000 | 245 | | | - | - | - | - | - | - |
| Base | 475 | 750 | 210 | | | - | - | - | - | - | - |
| Base | 370 | 1000 | 245 | 230 | 270 | - | - | - | - | 250 | 280 |
| Base | 370 | 750 | 210 | 210 | 260 | - | - | - | - | 240 | 270 |
| Base | 370 | 500 | 155 | 170 | 230 | - | - | - | - | 210 | 260 |
| Midi | 260 | 500 | 200 | | | - | - | - | - | - | - |
| Midi | 260 | 330 | 150 | | | - | - | - | - | - | - |
| Midi | 260 | 250 | 130 | | | 210 | 250 | 210 | 250 | 230 | 280 |
| Midi | 260 | 200 | 108 | | | - | - | - | - | - | - |
| MiniV | 260 | 330 | 175 | | | - | - | - | - | - | - |
| MiniV | 260 | 250 | 142.5 | | | - | - | - | - | - | - |
| MiniV | 260 | 200 | 125 | | | 210 | 250 | 210 | 250 | 230 | 280 |
| Mini | 260 | 330 | 180 | | | | | | | | |
| Mini | 260 | 250 | 147.5 | | | - | - | - | - | - | - |
| Mini | 260 | 200 | 130 | | | 210 | 250 | 210 | 250 | 230 | 280 |
| Mini | 260 | 150 | 108 | | | | | | | 220 | 250 |
| Micro | 150 | 100 | 108 | | | | | | | 170 | 230 |
|
Paper Support - Set
| Equipment Status | Program Step STEP ZERO |
Burn hazard.Allow the surfaces to cool down before starting any work on it.The surfaces can be hot.
Set the distance A between the Paper support by turning the Screw. Make sure the packaging material is centred between the Paper support.During Production
Check that the paper support is not damaging the inner side of the material web.
A (mm) = 1.5 +0.3/-0
- Paper support
- Screw
Paper Support - Set
| Equipment Status | Program Step step zero |
Burn hazard.Allow the surfaces to cool down before starting any work on it.The surfaces can be hot.
- Loosen the Screw.
- Set the distance A between the paper supports. Make sure the left Paper support is pressing the packaging material against the strip applicator roller. See Procedure Strip Applicator Version 1 - Set Alignment.
- Tighten the Screw.
- Check during production that the paper support is not damaging the product side of the material web.

A (mm) = 1.5 +0.5/-0
- Paper support
- Screw
- Loosen the Screw.
- Set the distance B, between the Wheel and the paper support, with a 2mm feeler gauge.
- Tighten the Screw.

B (mm) = 2 ±1
- Screw
- Wheel
Paper Support - Set
| Special Equipment | Template, TP No. 3431312-0000 |
Burn hazard.Allow the surfaces to cool down before beginning any work on it.The surfaces are hot.
- Adjust the distance A between the Paper support by adjusting the Nut. Make sure that the packaging material is centred between the Paper support.
| Hygiene Level | A (mm) |
| AD | 1.5 +0.5/-0 |
| XH | 1.5 +0.3/-0 |
- During production, check that the Paper support are not damaging the inner side of the material web.

- Paper support
- Nut
To adjust the upper plate and the position of the LS applicator rollers:- Loosen the Screw and the Screw.
- Set the Eccentric screw to 0.
- Tighten the Screw and the Screw.

Front Side

Back Side
- Screw
- Screw
- Eccentric screw
To adjust the lower plate and the parallelism between the packaging material and the mangle roller:- Loosen the Screw.
- Set the Eccentric screw to 0 and tighten the Screw.

- Screw
- Eccentric screw
To adjust the strip applicator alignment to the packaging material:- Remove the Nut, the Washer, the Spring, and the outer half of the Wheel.

- Nut
- Washer
- Spring
- Wheel
- Put the Template (TP No. 3431312-0000) on the Axle.
- Loosen the two Screws.
- Move the strip applicator horizontally to adjust the distance B between the Template and the Packaging material.Note: Make sure that the template only touches the packaging material. If the template puts pressure on the packaging material it results in wrinkles.

B (mm) = 0
- Template
- Axle
- Screws
- Packaging material
- Tighten the Screws.
- Remove the Template.
- Assemble in the reverse order.
Strip Pre-heater - Check Strip Position
| Equipment Status | Program Step PRODUCTION |
Burn hazard.Allow the heater to cool down before starting any work on it.The heater can be hot.
Risk of crushing.Be careful when working near the moving parts.The machine contains moving parts that can crush.
During production, check that the Strip is correctly positioned on the Applicator roller.If the Strip moves back and forth on the Applicator roller, adjust the Strip pre-heater according to the Strip Pre-heater - Set Holder on page Strip Pre-heater - Set Holder. The strip movement on the applicator roller must be set to a minimum.
- Strip
- Applicator roller
- Strip pre-heater
Strip Pre-heater - Set Air Pressure
| Equipment Status | Program Step HEATING |
Set the air pressure to 40 kPa (0.4 bar) by turning the Hand wheel on the Pressure regulator.
- Hand wheel
- Pressure regulator
Strip Pre-heater - Set Strip Slot
| Equipment Status | Program Step STEP ZERO |
Burn hazard.Allow the heater to cool down before starting any work on it.The heater can be hot.
Note: The distance between the Lid and the Heater must be measured and set in a non heated condition.- Measure the distance A between the Lid and the Heater by using a feeler gauge.
- If necessary, set the distance A, loosen the four Screw, and move the Lid to the correct position.
- Tighten the Screw.

Bottom view
A (mm) = 0.7 ±0.1
- Lid
- Heater
- Screw
Strip Pre-heater - Change Heater Element
| Equipment Status | Power must be turn OFF.
|
Hazardous Voltage.The main power supply disconnector must be switched off and secured with a lock before changing the heater element.Will shock, burn or cause death.
Burn hazard.Allow the heater to cool down before starting any work on it.The heater can be hot.
- Disconnect the Thermocouple.
- Disconnect the Pneumatic hose.
- Disconnect the inductive switch Cable.

- Thermocouple
- Pneumatic hose
- Cable
- Remove the Screw, Cable shoe and earth cable, Lock washer, and Holder.
- Disconnect the Heater cable from the connection box.
- Remove the Screw and washer and remove the strip pre-heater unit from the machine. Place the strip pre-heater unit on a clean suitable working area.
- Change the Heater element.
- Assemble the strip pre-heater in the reverse order.

Reverse angle
- Screw
- Cable shoe and earth cable
- Lock washer
- Holder
- Heater cable
- Screw and washer
- Heater element
Basic Settings
| Basic settings | Base | Midi | Mini | Micro |
| Temperature (⁰C) | Pressure (bar) | Temperature (⁰C) | Pressure (bar) | Temperature (⁰C) | Pressure (bar) | Temperature (⁰C) | Pressure (bar) |
| TT Mini 200ml /jl Al CLC/C Duplex 260mN IC | | | | | 100 | 0.4 | | |
Strip Magazine - Set Rolls
| Equipment Status | Program Step STEP ZERO |
- Check that the rolls move easily.
- Check that the edges of the strip are not stretching.
- If the strip is not centred above the notch on the Pad, adjust the position of the Roll by moving the Plate.
- Set the Strip holder to the distance A below the strip.

A (mm) = 0.5 +0.5/-0
- Pad
- Roll
- Plate
- Strip holder
Hub - Check
| Equipment Status | Program Step STEP ZERO |
| Consumables | Thread locker: TP No. 351532-0000 |
- Check that the Hub rotate freely.
- Check that the bobbins are securely attached to the hubs. If necessary, set the Spring-loaded ball to protrude the distance A.Note: Secure the Screw with thread locker.

A (mm) = 2 ±0.5
- Hub
- Spring-loaded ball
- Screw
Brake Arm - Set Distances
| Equipment Status | Program Step STEP ZERO |
- Set the distance A for the Brake arm and Brake arm. Adjust with the Screw.
- Set the distance B. Adjust with the Nut.
- Set the distance C. Adjust with the Nut.Note: When rotating the hub by hand, a resistance must be caused by the Roller. If not, adjust the Nut and Nut until there is a resistance.
- Move the Brake arm until the Roller just leaves the Hub.
- Adjust the Screw until it just reaches the Roller in position according to item d). Repeat the procedure for the Brake arm.Note: Use the distances as guidelines. The important thing is to get a proper functionality.
| Distance (basic setting) | Base/Midi | Mini/Micro |
| A (mm) | 132 | 131 |
| B (mm) | 115 | 120 |
| C (mm) | 45 | 48 |

Side 2 illustrated
- Brake arm
- Brake arm
- Screw
- Nut
- Nut
- Roller
- Hub
- Screw
Heating Device - Check
| Equipment Status | Program Step AIR ON |
Burn hazard.Allow the heating device to cool down before starting any work on it.The heating device can be hot.
- Check that the movements of the cylinder are smooth. If necessary, set the flow control valves. See Procedure Heating Device - Set Position on page Heating Device - Set Position.
- Check the positions of the Proximity switch. The proximity switch must not be activated until the Splice block reaches the pad.Note: See illustration on next page.
Risk of crushing.Remove the fuse to prevent the parts from moving while you are working.There are moving parts in the machine.
Remove the fuse.
- Check that the Spring is not stuck or damaged. Change, if required.
- Check the Splice block for cracks.
- Check that there are no air leaks in the Cooling air flow connection.
- Check that the Screw and Screw are well tightened.
- Install the fuse.

- Proximity switch
- Cooling air flow connection
- Screw
- Spring
- Splice block
- Screw
Heating Device - Check Pad
| Equipment Status | Program Step STEP ZERO |
Burn hazard.Allow the heating device to cool down before starting any work on it.The heating device can be hot.
- Check that the Pad is not damaged.
- If the pad is damaged, loosen the Screw and turn the pad 180º. If the pad is damaged at both ends, change the pad.
- Tighten the Screw.

- Pad
- Screw
Machine Body - Set Photocells
| Equipment Status | Program Step STEP ZERO |
Photocells for Empty Reel
The pair of Photocell, sender and Photocell, receiver record empty reel.- Set Photocell, sender and Photocell, receiver by adjusting the ball joints until the photocells have contact with each other. The red lamp on the Photocell, receiver indicates when the photocells have contact.
Photocells for Web Slack
The Photocell, sender and Photocell, receiver record the upper web slack and the Photocell, sender and Photocell, receiver the lower web slack.Note: Position for the Photocell, receiver and Photocell, receiver differs depending on bottom size. See instructions on next pages.
- Photocell, sender
- Photocell, receiver
- Photocell, sender
- Photocell, receiver
- Photocell, sender
- Photocell, receiver
- Install the Photocell, receiver in the Bracket according to the table below.
| Bottom Size | Use Holes: |
| Base, Midi & Mini | A |
| Micro | B |
- If there is need for further adjustments, move/bend the Bracket for the Photocell, transmitter. The red lamp on the Photocell, receiver indicates when the photocell has contact.

- Bracket
- Photocell, transmitter
- Photocell, receiver
- Bracket
- Install the Photocell, receiver to the Frame according to table below.
| Bottom Size | Use Holes: |
| Base | C |
| Midi, Mini & Micro | D |
- Set the Photocell, receiver by adjusting the ball joint. If necessary, bend also the Photocell bracket until they have contact with each other. The red lamp on the Photocell, receiver indicates when the photocell has contact.

- Photocell bracket
- Photocell, receiver
- Frame
Machine Body - Set Photocells
| Equipment Status | Program Step Step Zero |
Photocells for Empty Reel
The pair of Photocell, sender and Photocell, receiver record empty reel.- Set Photocell, sender and Photocell, receiver by adjusting the ball joints until the photocells have contact with each other. The red lamp on the Photocell, receiver indicates when the photocells have contact.
Photocells for Web Slack
The Photocell, sender and Photocell, receiver record the upper web slack and the Photocell, sender and Photocell, receiver the lower web slack.Note: Position for the Photocell, receiver and Photocell, receiver differs depending on bottom size. See instructions on next pages.
- Photocell, sender
- Photocell, receiver
- Photocell, sender
- Photocell, receiver
- Photocell, sender
- Photocell, receiver
- Install the Photocell, receiver on the Bracket.
- If there is need for further adjustments, move/bend the Bracket for the Photocell, transmitter . The red lamp on the Photocell, receiver indicates when the photocell has contact.

- Bracket
- Photocell, transmitter
- Photocell, receiver
- Bracket
- Install the Photocell, receiver on the Frame.
| Bottom Size | Use Holes: |
| Base | A |
| Midi, Mini & Micro | B |
- Set the Photocell, receiver by adjusting the ball joint. If necessary, bend also the Photocell bracket until they have contact with each other. The red lamp on the Photocell, receiver indicates when the photocell has contact.

- Photocell bracket
- Photocell, receiver
- Frame
Fan System - Set Pressure Switch
| Equipment Status | Power must be turn OFF.
|
Hazardous voltage.The main power supply disconnector must be switched off and secured with a lock before starting any work on the protective covers, connections, or cables.Will shock, burn, or cause death.
Setting of Pressure Switches V11B0224, V11B0225 and V11B0226.- Adjust upper/lower switching point by turning the Dial.
- For higher switching point (higher pressure), turn the Dial to the right.
- Allow pressure to increase gradually (do not exceed the maximum pressure limit) and adjust desired switching point with Dial.
- Check the upper and lower switching point by raising and lowering the pressure several times and make any necessary adjustments.Note: Do not turn the Dial outside the printed scale. (The switching contact changes from NC (1-2) to NO (1-2)).
| Basic setting 50 Hz | Basic setting 60 Hz |
| V11B0225 = 4500 Pa | V11B0225 = 5000 Pa |
| V11B0224 = 3000 Pa | V11B0224 = 4000 Pa |
| V11B0226 = 1100 Pa | V11B0226 = 1500 Pa |

The pressure switches indicate the following:V11B0225: Dirty filter, level 2V11B0224: Dirty filter, level 1V11B0226: Too low air pressure
- Dial
Fan System - Clean Filter
| Equipment Status | Program Step STEP ZERO |
- Loosen the clips and remove the Cover.
- Lift out the Filter insert.
- Rinse the Filter insert using water or soap solution. If using soap solution, rinse with water afterwards. Dry the Filter insert using compressed air or put the Filter insert in a clean place to dry.Note: If the filter insert is not dry when inserted in the machine, an alarm may appear.
- Assemble in the reverse order when the filter insert is dry.

- Cover
- Filter insert
Functional Description
The vaporised hydrogen peroxide from the pre-treatment evaporators is lead through hoses and out the peroxide spray nozzles inside the Pre-treatment box. See also Chapter Carton Section. The Pre-treatment box collect and transport the excessive vaporised hydrogen peroxide to the Condenser where the hydrogen peroxide vapour condensates and is lead to the Buffer tank on side 2 of the ASU.Note: The hydrogen peroxide from the condenser has a concentration of >3%.The tank is provided with a Float switch, making sure that the Buffer tank is partially filled with water. During production, the buffer tank will be filled with hydrogen peroxide to a certain point. When the float switch has reached that level, more water will be added to dilute the hydrogen peroxide to a concentration of <3%. The buffer tank is then drained.
- Pre-treatment box
- Condenser
- Buffer tank
- Float switch
Pre-treatment ASU - Check Buffer Tank Float Switch
| Equipment Status | Program Step STEP ZERO |
- Make sure that the float switch functionality is as described in the illustration below. If necessary, change the float switch.
| Filling water | First water level reached |
 |
| Diluting H2O2 with water | Empty buffer tank |
 |
1 Black2 Brown3 Blue4 Grey
Pre-treatment ASU - Change Pre-treatment Box Seals
| Equipment Status | Program Step STEP ZERO |
| Special Equipment | Ladder TP No. 2974506-0100 Brush Soft cloth |
| Consumables | Alkali solution (Manual Cleaning) Alcoholic solution (Isopropanol 70%) |
Hazardous substances.Always wear personal protective equipment.Contact with corrosive chemicals can be hazardous to your health.
Burn hazard.Allow the pre-treatment box and quick-connection to cool down before starting any work near it. If this is not possible, use caution when working near the pre-treatment box.The pre-treatment box and the quick connection are hot.
- Disconnect the Quick-connection to the peroxide unit.
- Loosen the Union nut.

- Quick-connection
- Union nut
Note: Mount the pre-treatment ladder on the frame of the Carton Section.- Lift the Pre-treatment box straight up from the Holder. Then slant the pre-treatment box and move it to the end of the rail.
- Support the Pre-treatment box and remove it from the machine.
- Place the Pre-treatment box on a clean suitable area.
- Loosen the Wing nut and remove the Lid.

- Pre-treatment box
- Holder
- Wing nut
- Lid
- Remove the Nut, the Plate, and the Seal.
- Clean thePre-treatment box with a brush and a cloth. Wipe the pre-treatment box dry.
- Assemble the new Seal and the Plate, and tighten the Nut.Note: Make sure that the Seal are correctly assembled in the pre-treatment box.

- Pre-treatment box
- Nut
- Plate
- Seal
- Spray disinfectant and wipe off the inside of the pre-treatment box Seal.
- Assemble the Lid and tighten the Wing nut.Note: Before mounting the pre-treatment box in the machine, always make sure that the union gasket is in place.
- Place the pre-treatment box on the rail of the Holder on the strip applicator unit in the ASU. Move the pre-treatment box along the rail and straighten it while carefully lowering.

- Pre-treatment box
- Wing nut
- Lid
- Seal
Burn hazard.Use caution when working near the quick-connection.The quick-connection can be hot.
Connect the Quick-connection to the peroxide unit.Note: An audible “click” from the Quick-connection ensures that the connection is fully engaged. Despite this, always make sure that the quick-connection is fully engaged by manually pulling the hose.- Tighten the Union nut.

- Quick-connection
- Union nut
Pre-treatment ASU - Change Valve Diaphragm
| Equipment Status | Program Step STEP ZERO |
Hazardous substances.Always wear personal protective equipment.Contact with corrosive chemicals can be hazardous to your health.
- Remove the Screw and washer and separate the Valve seat and the Actuator.
- Change the Diaphragm.
- Assemble the valve in the reverse order. Tighten the screws to an approximately torque of 1.5 Nm.

- Screw and washer
- Valve seat
- Actuator
- Diaphragm
Description
This chapter contains the maintenance procedures for the Carton Section.Cutting Device - Check Knives
| Equipment Status | Program Step step Zero |
| Special Equipment | Scale loupe or ruler |
- Check that the cut is perpendicular to the packaging material edge.
- Measure the distance between the Bottom fin crease and the Bottom edge on both sides of the blank.
- The distance must be 8.5±0.5 mm.
- The difference between A and B must not be greater than 0.5mm.
- See the OM - Package Checks for setting on the TPOP.
- Bottom fin crease
- Bottom edge
- Make sure that the cut is clean at the bottom edge, and not fraying.
- If the blanks are not cut perpendicular to the packaging material edge, check guiding bars, splice detector, bending roller, and drive rollers.
Cutting Device - Check Rod End
| Equipment Status | Program Step step Zero |
Risk of cutting.Be careful when working near them.The knifes in the cutting unit are sharp.
- Check the rod end, see arrow, for play.
- If necessary, change the rod end. See Procedure Paper Feed - Change Ball Bearing on page Paper Feed - Change Ball Bearing.
Cutting Device - Remove Cutting Device
| Equipment Status | Program Step step Zero |
Risk of cutting.Be careful when working near them.The knifes in the cutting unit are sharp.
- Remove the four Screw that hold the Web guide.
- Remove the four Bolt.
- Remove the Screw and disconnect the Rod end.

Magnification seen from the reverse angle.
- Screw
- Web guide
- Bolt
- Screw
- Rod end
- Remove the Plate by removing the Screw that hold them.
- Remove the Bolt and disconnect the Rod end.
- Lift the Plate and pull out the Cutting device.

- Plate
- Screw
- Bolt
- Rod end
- Plate
- Cutting device
Cutting Device - Install Cutting Device
| Equipment Status | Program Step step zero |
Risk of cutting.Be careful when working near them.The knifes in the cutting unit are sharp.
- Lift the Plate and install the Cutting device.
- Attach the Cutting device with the four Bolt.
- Attach the Web guide with the four Screw.
- Attach the Rod end with the Screw.

Magnification seen from the reverse angle.
- Plate
- Cutting device
- Bolt
- Web guide
- Screw
- Rod end
- Screw
- Attach the Plate with the Screw.
- Attach the Rod end with the Bolt.

- Plate
- Screw
- Rod end
- Bolt
Paper Feed - Check Counter Wheels
| Equipment Status | Program Step step zero |
- Release the Lever arm.
- Check that the wear surface of the Counter wheel is smooth and that the wheel is not oval.
- Make sure that the diameter A of the Counter wheel is larger than 68 mm.
- Repeat item Reference to Reference on the Lower counter wheel.
- Change any wheel that is damaged or worn.

- Lever arm
- Counter wheel
- Lower counter wheel
Paper Feed - Set Counter Wheel
| Equipment Status | Program Step step zero |
| Special Equipment | Template TP No. 2950400 |
- Set the Template against the Reference surface. Use the illustration below to find the Reference surface for side 1 and side 2.
- Loosen the Screw.
- Set the Counter wheel against the Template .
- Tighten the Screw.

Side 1Side 2
- Template
- Reference surface
- Screw
- Counter wheel
- Repeat the items a) to d) for the Counter wheel.
- Check that the knives cut the paper at a right-angle.

Side 1Side 2
- Template
- Counter wheel
Paper Feed - Set Flanges
| Equipment Status | Program Step Step Zero |
| Special Equipment | Template TP No. 2950400 |
- Set the Template against the Reference surface. Use the illustration below to find the Reference surface for side 1 and side 2.
- Loosen the Screw.

Side 1

Side 2
- Template
- Reference surface
- Screw
- Set the distance A and B on the template according to the table below.
- Set the Flange against the Template.
- Tighten the Screw.
| Side 1 | Side 2 |
| A (mm) | B (mm) | | A (mm) | B (mm) |
| Base | 40 | 266 | Base | 45 | 266 |
| Midi | 67.5 | 216 | Midi | 67.5 | 216 |
| Mini | 83.5 | 181 | Mini | 85 | 181 |
| Mini, prepared for volume330* | 85 | 181 | Mini, prepared for volume330* | 85 | 181 |
| Micro | 106 | 139 | Micro | 106 | 139 |
| *If the pre-folder bracket has two sets of hole patterns for assembling the actuator, the machine is prepared for Mini330. |

Side 1

Side 2
- Template
- Reference surface
- Screw
- Flange
- Remove the Bolt and the Bracket.
- Set the distance C on the template according to the table below.
- Set the Template against the Reference surface. Always use the reference surface on the plate closest to you.
- Loosen the Screw.
- Set the Flange against the Template.
- Tighten the Screw.
- Install the Bracket with the Bolt.
| Side 1 | Side 2 |
| C (mm) | C (mm) |
| Base | 306 | 311 |
| Midi | 283.5 | 283.5 |
| Mini | 264.5 | 266 |
| Mini, prepared for volume330* | 266 | 266 |
| Micro | 245 | 245 |
| *If the pre-folder bracket has two sets of hole patterns for assembling the actuator, the machine is prepared for Mini330. |

Side 1

Side 2
- Template
- Bolt
- Bracket
- Reference surface
- Screw
- Flange
Paper Feed - Set Wheels
| Equipment Status | Program Step step zero |
- Make sure that the Level arm is in locked position.
- Loosen the Screw and turn the Shaft until there is no play between the Counter wheel and the Roller. Set the distance A. The drive wheel rubber surface will be slightly compressed.Note: The Shaft has a 14 mm key grip.
- Tighten the Screw and check the setting.
- Repeat the procedure for the Counter wheel.

A (mm) = 0 ±0.05
- Level arm
- Screw
- Shaft
- Counter wheel
- Roller
- Counter wheel
Paper Feed - Set Proximity Switch
| Equipment Status | Program Step step zero |
- Loosen the Nut.
- Set the distance A between the Sensor and the Rivet.
- Tighten the Nut.

A (mm) = 1 ±0.5
- Nut
- Sensor
- Rivet
Paper Feed - Change Servomotor
| Equipment Status | Power must be turn OFF.
|
Hazardous voltage.The main power supply disconnector must be switched off and secured with a lock before starting any work on the electrical equipment.Will shock, burn, or cause death.
- Disconnect the electric cables on the Connection.
- Loosen the Grub screw in the Coupling.
- Loosen the Screw and pull out the Servomotor.
- Remove the Coupling from the Servomotor.
- Assemble the Coupling to the new Servomotor shaft, make sure that the distance A is achieved between the Servomotor and the Coupling.
- Tighten the Grub screw lightly on the Coupling.Note: The Coupling is asymmetric. The distance C is longer than B. The Coupling must be assembled with the distance C towards the Servomotor.
- Slide the Servomotor in place.
- Tighten the Screw and the Grub screw.
- Connect the electric cables on the Connection.

A (mm) = 11 ± 0.5
B
- Connection
- Grub screw
- Coupling
- Screw
- Servomotor
Paper Feed - Change Photocell
| Equipment Status | Program Step step zero |
- Disconnect the Cable.
- Remove the Screw.
- Change the Photocell.
- Assemble in the reverse order.

- Cable
- Screw
- Photocell
Paper Feed - Set Magnetic Design Reader
| Equipment Status | Program Step STEP ZERO |
| Special Equipment | Datacable TP No. 3457827 Memorystick box TP No. 3457828 |
Risk of cutting.Be careful when working near the knives.The knives in the paper feed are sharp.
Note: The cutting position can be adjusted on the TPOP.- Connect the Magnetic design reader to the HyperTerminal. For more information about how to set up the HyperTerminal see Paper Feed - Set Magnetic Design Reader Parameter.
- Loosen the Screw.
- Set the signal strength (Level) to 100 to 150 using the Adjusting screw.
- Tighten the Screw
- Magnetic design reader
- Screw
- Adjusting screw
- Loosen the Screw.
- Set the horizontal position of the Magnetic design reader using the Adjusting screw.The Marking on the Magnetic design reader must correspond to the centre of the Magnetic mark on the packaging material.
- Tighten the Screw.
- Close the doors and run blanks.Check the align slider bar in HyperTerminal.
- Repeat item Reference to item Reference until the current align is in the centre of the slider bar (±60).
- Magnetic design reader
- Screw
- Adjusting screw
- Marking
- Magnetic mark
- Loosen the Screw.
- Set the signal strength (Level) as close as possible to 254 using the Adjusting screw.
- Tighten the Screw
- Disconnect the HyperTerminal.
- Magnetic design reader
- Screw
- Adjusting screw
Paper Feed - Set Magnetic Design Reader Parameter
| Equipment Status | Program Step step zero |
| Special Equipment | Serial RS232 communication adaptor cable Datacable TP No. 3457827 Memorystick box TP No. 3457828 |
Setup HyperTerminal
If it is the first time the HyperTerminal program is used, you need to make some settings.- From the Windows start menu, select: .
- Give the new connection a relevant name, for example MDR_com1, and click
OK. - In the Connect using field, select COM_1 and click OK.
- Set the port settings to; 9600, 8, None, 1, None and click OK.

- Connect using field
- OK
- OK
- Select and in the Emulation field select ANSIW.
- Click OK.
- Close the HyperTerminal and save the settings.

- Emulation field
- OK
Set Parameters
For the web cut control to run correctly, the parameters "Magnetic Mark Polarity" in the Magnetic Design Reader must be set to "1" according to below. This parameter is by default set to "0" in the firmware.- Connect the adapter cable between the PC and the middle connector with three pins on the Magnetic Design Reader sensor.
- From the Windows start menu, select: Program→Accessories→Communications→HyperTerminal.
- Type local to open the Main Menu.
- Type c to select CONFIGURATION.
- Type e to open the Edit Mode.
- Press ENTER once, scroll down to select MAGNETIC MARK POLARITY.
- Type 1 and press ENTER.
- Press ENTER five times, and edit mode is terminated
- Check that the Magnetic Mark Polarity is set to 1.
- Press ESC once to go to Main Menu.
In the main menu, other folders and parameters can be selected and adjusted in the same way as above. Be sure not to fiddle with any setting if you do not know what you are doing.
Read Magnetic Design Reader Sensor Values Online
It is possible to read values online with the HyperTerminal that is connected to the Magnetic Design Reader.- Type
local to open the Main Menu. - Type
d to select Runtime Data.The row Level/Align shows the last update of the following:| Value: | Comment: |
| Level - signal strength:0 to 254 | Highest cutting accuracy is achieved if signal strength is maximised. Aim to have stable signal strength at 254. |
| Align - side align:-254 - 0 - +254corresponds to-2 - 0 - +2 mm | Normal ±60 corresponds to ±0.5mm depending on side positioning of the Magnetic Design Reader sensor and web side cut. |
- Return to the Main Menu.
- Type
y to select Quick level reading.The window shows the following:| Slider Bar: | Comment: |
| Signal Level | Values related to 0 to 254 and actual value and accumulated peak value are shown. |
| Side Align | Values related to -254 - 0 - +254 and actual value shown. |
- Press R to reset peak value.
Paper Feed - Set Pressure Unit
| Equipment Status | Program Step step ZERO |
- Remove the two Nut and lift out the pressure unit.
- Remove the Retaining ring and the Arm.
- Tighten the Spring by two full turns to the left.
- Install in the reverse order.

- Nut
- Retaining ring
- Arm
- Spring
Paper Feed - Adjust Photocell
- Verify that the Bracket is installed on the correct side.
| S1 | 2934125-0000 |
| S2 | 3106203-0000 |

- Bracket
- Make sure that the distance A between the Photocell and the Covering plate is approximately 430mm.
- If the distance A differs more than a few millimetres from the target distance, the Bracket has not been installed correctly.

A = 430mm
- Photocell
- Covering plate
- Make sure that the Photocell reads on the lowest part of the paper feed.Note: Make sure that the Photocell does not read on the Prefolder.

- Photocell
- Prefolder
Paper Feed - MDR Position Adjustment
| Equipment Status | Program Step STEP ZERO |
- To adjust height of bracket for wheel, loose the two Nut.
- Adjust height , correct adjustment is when the Centre of Wheel is placed in the centre of the Centre of MDR Sensor.

- Nut
- Centre of MDR Sensor
- Centre of Wheel
To adjust wheel sidewards
- Loosen the two Nut.
- Adjust sideways. Centre of the Wheel should be in line with the mark.

- Nut
- Centre of the Wheel
Paper Feed - Check MDR Wheel and Bushing
- Release the Wheel from the magnetic design reader by hand. Turn around the Wheel to check the wear on the bushings.
- Make sure that the Wheel does not wobble. Change, if necessary. See Procedure Paper Feed - Change MDR Wheel and Bushing.

- Wheel
Paper Feed - Change MDR Wheel and Bushing
- Remove the Screw, the Washer and the Shaft.
- Change the Wheel and replace theBushing.
- Assemble in the reverse order.

- Shaft
- Wheel
- Bushing
- Washer
- Screw
Splice Detector - Set
| Equipment Status | Program Step step zero |
- Loosen the Screw.
- Set the distance A.
- Tighten the Screw.

A (mm) = 172 ±1
- Screw
- Adjust the Screw until the Arm covers half the Sensing surface of the Sensor. The Sensor is to be actuated, and its light-emitting diode is lit.
- Set the distance B between the Arm and the Sensor.
- Loosen the Screw and position the Roller to obtain the distance C between the Roller and the Counter roller.
- Tighten the Screw.
- Check that the light-emitting diode goes off if a 0.9 mm feeler gauge is inserted between the Roller and the Counter roller.
- If this is not the case, the entire unit can be turned in order to obtain a more favourable angle for the Roller by loosening the Screw.
- Screw
- Arm
- Sensor
- Sensing surface
- Screw
- Roller
- Counter roller
- Screw
- Set the distance D between the Flange and the Roller.
Splice Detector - Change Inductive Sensor
| Equipment Status | Program Step step zero |
- Disconnect the Cable.
- Remove the Screw.
- Change the Inductive sensor.
- Assemble in the reverse order.

- Cable
- Screw
- Inductive sensor
Splice Detector - Overhaul
| Equipment Status | Program Step step zero |
Bushings, Holder
- Remove the unit from the cutting unit shaft by loosening the Screw.
- Loosen the Screw and remove the Arm.
- Pull out the Holder with the Ball bearing.
- Force the Bushing out.
- Change the Ball bearing and the Bushing.
- Check for excessive play between the shaft of the Holder and the house. If necessary, change the Holder.
- Assemble in the reverse order.
- Set the splice detector. See procedure Ball Bearing (Separately) on page Ball Bearing (Separately).

- Screw
- Screw
- Arm
- Holder
- Ball bearing
- Bushing
Ball Bearing (Separately)
This procedure can be done with the unit fitted on the cutting unit shaft.- Loosen the Grub screw and remove the Stop ring.
- Change the Ball bearing.
- Assemble in the reverse order.

- Ball bearing
- Grub screw
- Stop ring
Photocell Unit - Set Guide Finger
- Make sure that packaging material is prepared through the cutting unit.
- Make sure that the cutting unit is in an open position.
- Loosen the Screw.
- Place the Guide finger as close as possible to the packaging material. Make sure the Guide finger does not touch the packaging material.
- Tighten the Screw.
- Repeat items a) to e) on the other side of the Web guide.

- Screw
- Guide finger
- Web guide
Photocell Unit - Set Reading Points
| Equipment Status | Air must be turn ON.
|
- Loosen the Screw.
- Put a strip of packaging material under the Photocell unit.

- Screw
- Photocell unit
- Make sure that the reading points from the Photocell unit are in the centre of their respective Barcode.
- Tighten the Screw.

- Screw
- Photocell unit
- Barcode
Supply Monitor- Set Photocell Receivers
| Equipment Status | Program Step air on |
Set the receiver according to the illustration. Check that the beam does not shine through the packaging material. If it does shine through, adjust the receiver to a lower value than Max.Pre-Folder - Check Air Cylinder
| Equipment Status | Program Step step zero |
- Check that the air cylinder is functioning properly and moves easily.
- Step the machine up to AIR ON.
- Check that there is no air leakage from the hoses or the cylinder. On Festo machines, use the air service tool. See Air Service Tool Description.
Pre-Folder - Set
2000 | Equipment Status | Program Step step zero |
| Special Equipment | Template TP No. 2758258-0000 |
Setting of Angle Piece
With the pneumatic cylinder in fully extended position, check the distance A. If not possible to achieve the distance A, check:- for incorrect assembly.
- for insufficient stroke of the cylinder.
- if something is bent.
- Adjust the cylinder piston to set the distance A.
- Check that the Mounting bracket and the Cylinder are aligned according to B, see illustration below, before mounted in the pre-folder Frame. The Cylinder mounting plate has asymmetrical holes and the Mounting bracket has oval holes.If needed, reset the parallelity of the angle piece with the template.
- Loosen the four Screw or the four Screw.
- Adjust the Angle piece with the Template to be parallel with the Frame.
- Tighten the Screw or the Screw.

A = 26.5 ± 1 mm
- Mounting bracket
- Cylinder
- Frame
- Cylinder mounting plate
- Screw
- Angle piece
- Template
- Screw
Aligning Rods
Note: The Linear actuator must not be mounted when aligning the rods.- Pull the Frame manually upward against the upper bracket. Tighten the Screw. Push the Frame downward to the bottom bracket.
- Tighten the Screw. Make sure that the frame of the pre-folder moves up and down easily without forcing it.

- Angle piece
- Frame
- Linear actuator
- Screw
- Screw
Aligning of Pre-Folder
- Align the Frame to be parallel with the Bracket using the Template.
- Connect the linear actuator.

- Frame
- Bracket
- Template
- Pull the packaging material through the pre-folder and make sure it is in the correct cutting position. If not, the setting of the pre-folder will be wrong.Note: For activation and fine adjustment of the pre-folder, see Machine Settings, Set Pre-folder, in the OM-Package Checks.
Pre-Folder -Set Inductive Switch
| Equipment Status | Program Step step zero |
- Remove the Plate from the Bracket.
- Set the distance A of the Inductive switch outside of the plate.
- Put back the Plate on the Bracket.
- Adjust the Plate in height:
- Push the pre-folder towards its lower position, approximately five mm from its lowest position, until the Inductive switch responds.
- Tighten the screws for the Plate.Note: The bracket is only used to verify that the pre-folder is in its mechanical home position. It can not be used to set the position of the pre-folder.Note: When the Pre-folder is selected on the TPOP, it performs a position reset by first moving to home position and then to production position.

A (mm) = 17
- Plate
- Bracket
- Inductive switch
- Photocell unit
Pre-Folder - Set Motor Drive Control
| Equipment Status | Program Step step zero |
Risk of damage to the equipment.Make sure that the position of the bridges is set according to the illustration below.Incorrect supply polarity can damage the motor drive control.
Set the motor drive control found in connection box 1567716 and 1567721 according to the illustration.Pre-Folder - Change Air Cylinder
| Equipment Status | Program Step step zero |
- Disconnect the Hose.
- Loosen the Screw and the Screw.
- Loosen the four Screw to release the Frame.
- Loosen the Screw.
- Change the Air cylinder.
- Assemble in the reverse order.Note: There are oval holes in the Mounting bracket. Mount the cylinder aligned with the Mounting bracket.
- Set the pre-folder. See Procedure Pre-Folder - Set on page Pre-Folder - Set.Note: Make sure that the air hoses are secured and not interfering with moving arms or disturbing daily cleaning.

- Hose
- Screw
- Screw
- Screw
- Frame
- Screw
- Air cylinder
- Mounting bracket
Pre-Folder - Actuator Position
| Equipment Status | Program Step step zero |
The Pre-folder Bracket can have one or two sets of hole patterns. The hole patterns are used to assemble the actuator.
- Bracket
- Depending on the hole pattern, assemble the actuator in

Single hole pattern.

Double hole pattern. Theactuatorassembledindifferentpositions.
- Hole pattern
- Upper hole pattern
- Lower hole pattern
Note: Item is only valid for bottom format Mini.- Check the machine settings in the PLC for the pre-folder actuator position. See Procedure 7.9.4-1 Machine Settings in the PLC, section Main.
Pre-Folder - Set Pre-Folder Height
| Equipment Status | Program Step Step Zero |
| Special Equipment | Template TP No. 2758259-0000 |
Note: Valid for machines with the actuator assembled in the lower hole pattern. See .Valid for: Equipment with Mini- Loosen the Screw and the Screw.
- Set the height B of the Pre-folder.
- Tighten the Screw
- Loosen the Screw.
- Set the height A of the Inductive switch.
- Tighten the Screw.

A (mm) = 70 ±1
B (mm) = 190 ±1
- Screw
- Screw
- Pre-folder
- Inductive switch
- Screw
Valid for: Equipment with Midi, Base- Remove the Linear Actuator. Use Template to set the distance A and the parallelity between the Bracket and the Roller.
- Connect the Linear Actuator.

A = 14.5 ± 1 mm
- Linear Actuator
- Template
- Bracket
- Roller
Folder - Set Folding Plates
| Equipment Status | Program Step step zero |
- Remove the Lead plate.
- Remove the link head (not shown on picture).
- Attach the Template and the Template.
- Adjust on the Template to align the Folding plate with the Folding bar as illustrated below.

- Lead plate
- Folding bar
- Template
- Folding plate
- Nut
- Template
- Template
- Loosen the Nut.
- Set each folding plate separately, according to the table below, with the Template placed between the Folding plate and the Folding bar.
- Tighten the Nut.
- Fit the Lead plate.
| The Template TP No. | Distance A (mm)(without template) |
| Base | 1477274 | 6.0 ±0.15 |
| Midi | 1502771 | 5.0 ±0.15 |
| Mini | 1295843 | 4.5 ±0.15 |
| Micro | 1295843 | 4.5 ±0.15 |
- Lead plate
- Folding bar
- Template
- Folding plate
- Nut
- Template
- Template
Folder - Set Folding Bars
| Equipment Status | Program Step |
| Special Equipment | Template TP No.185776-0101 (BASE) Template TP No.1185776-0102 (MIDI) Template TP No.1185776-0103 (MINI) Template TP No.1185776-0104 (MICRO) |
- Inch the machine to top position of the Folding plate, (MSP 525) or (MSP 1325).
- Set the distance A, alternative the distance B, between the Carrier belt and upper side of the Folding plate. The setting is to be made at the Link head (or at the Cylinder piston rod ).
- If the folding plates are not parallel with the carrier belt in longitudinal direction (that is the distances at F and G are not the same), adjust by loosening the four Screw of the Rod and tilt the folding plates.
- Remove the Screw and lean the piston rod toward the frame of the folding unit.
- Folding plate
- Carrier belt
- Link head
- Cylinder piston rod
- Screw
- Rod
- Screw
- Mount the Template part A, the Template part B, the Templates parts C and D, and the Template part E by using the Screw.
- Loosen the Screw slightly.
- By turning the Wing nut it is possible to raise or lower the Folding bar while keeping them parallel to the folding plates.
- When the Template part E of the template has reached the carrier belt, the height of the folding bars is correct.Note: Use a 0.05 mm feeler gauge between the belt and the Template part E to check that the Wing nut is not tighten too much. When the feeler gauge starts to make a resistant force, the tightening torque is then correct.
- Tighten the Screw.
- Remove the template and tighten the Cylinder piston rod and the Screw (see previous page).
- Template part A
- Template part B
- Templates parts C and D
- Template part E
- Screw
- Screw
- Wing nut
- Folding bar
Setting of Folding Bars without Template
| Distance | Base (mm) | Midi (mm) | Mini (mm) | Micro (mm) |
| A | 81.5 ±0.5 | 64.0 ±0.5 | 52.0 ±0.5 | Not valid for Micro |
| B | 74.5 ±0.5 | 64.0 ±0.5 | 52.0 ±0.5 | Not valid for Micro |

- Folding plate
- Carrier belt
Folder - Lubricate
| Equipment Status | Program Step step zero |
| Special Equipment | Grease gun: TP No. 3366407-0000 |
| Consumables | Grease: TP No. 344407-0000 |
There are two grease nipples on each side of the machine. Use this procedure for each grease nipple.- Use a Grease gun to lubricate grease into the Grease nipple.Note: Remove surplus lubrication. Too much grease might force the ball bushings out of position.

- Grease gun
- Grease nipple
Folder - Remove
| Equipment Status | Program Step step zero |
Note: The heater must be removed before the folder.- Remove the Screw.
- Remove the Slide rail.
- Remove the Fibre optic sensor.
- Remove the Screw and pull the folder unit out.

- Screw
- Screw
- Slide rail
- Fibre optic sensor
Folder - Change Link Heads
| Equipment Status | Program Step step zero |
- Note the c/c distance before removing the Link arm.Note: When measuring the c/c distance, check that the cylinders are in minus position.
- Mark the Pneumatic coupling and disconnect them.
- Remove the Screw and the Link arm.
- Change the Link head.
- Assemble in the reverse order and set the c/c distance.

- Link arm
- Screw
- Link head
- Pneumatic coupling
Folder - Change Photocell Unit
| Equipment Status | Program Step step zero |
- Loosen the Screw.
- Change the Photocell holder.Note: For Base, Midi and Mini, use the lower holes.Note: For Micro, use the upper holes.
- Tighten the Screw.

- Screw
- Photocell holder
LS-Heater - Check Element (Heating Cartridge)
| Equipment Status | Power must be turn OFF.
|
Hazardous voltage.The main power supply disconnector must be switched off and secured with a lock before starting any work on the electrical equipment.Will shock, burn, or cause death.
- Disconnect the power cables inside the connection box.
- Check the resistance in the Connection box. The resistance must be according to the table below.
- Change any element with incorrect resistance. See Procedure LS-Heater - Change Element (Heating Cartridge) on page LS-Heater - Change Element (Heating Cartridge).
| Inner heating element | Outer heating element |
| Connections | Resistance (Ω) | Connections | Resistance (Ω) |
| 3 - 1 | 35 | 6 - 5 | 35 |
| 3 - 2 | 35 | 6 - 4 | 35 |

- Connection box
LS-Heater - Set Cooling Bodies
| Equipment Status | Program Step step zero |
| Special Equipment | Template Base TP No. 1477310 and 1477312 Template Midi TP No. 1502290 Template Mini TP No. 1521728 Template Micro TP No. 2605291 |
Burn hazard.Allow the heater to cool down before starting any work on it.The heater can be hot.
- Loosen the four Nut.
- Set the distance A between the Cooling body with the Template or with a feeler gauge.
- Tighten the Nut.
| Bottom Format | A |
| Base | 1 +0/-0.1 mm |
| Midi | 1 +0/-0.1 mm |
| Mini | 1 +0/-0.1 mm |
| Micro | 0.8 +0.1/-0 mm |

- Nut
- Plate
- Cooling body
- Template
LS-Heater - Clean
| Equipment Status | Program Step step zero |
Burn hazard.Allow the heater to cool down before starting any work on it.The heater can be hot.
- Loosen the Nut on the two Outer cooling body.
- Move the Outer cooling body from the lid and out of the way as far as the hoses permit.
- Remove the plastic deposits from the surfaces.Note: Do not use tools that make scratches in the cooling bodies.
- Set the cooling bodies. See Procedure LS-Heater - Set Cooling Bodies on page LS-Heater - Set Cooling Bodies.

- Nut
- Outer cooling body
LS-Heater - Change Thermocouple
| Equipment Status | Program Step step zero |
| Consumables | Anti-seize: TP No. 344418-0000 |
Burn hazard.Allow the heater to cool down before starting any work on it.The heater can be hot.
- Disconnect the Female plug from the Thermocouple.
- Loosen the Nut and pull out the Thermocouple.
- Mark with a Marker outside the Nut on the new Thermocouple, so that the distance A is maintained during fitting.
- Assemble the Thermocouple in the oven, and keep an eye on the mark so that the distance A has not been changed.
- Apply the anti-seize to the Nut and tighten.
- Connect the Female plug to the Thermocouple.

A (mm) = 90
- Nut
- Thermocouple
- Female plug
- Marker
LS-Heater - Change Element (Heating Cartridge)
| Equipment Status | Power must be turn OFF.
|
Hazardous voltage.The main power supply disconnector must be turned off and secured with a lock before starting any work on the electrical equipment. Will shock, burn, or cause death.
Burn hazard.Allow the heater to cool down before starting any work on it.The heater can be hot.
Note: Remove the LS-Heater before changing the elements.Note: Check which elements have to be changed. See Procedure on page .The illustration is also on next page.- Start the lifting cycle for LS-Oven.
- Secure the oven with a bracket to prevent an accidental drop.Note: No settings are necessary if this step is completed.
- Loosen the Cable gland.
- Remove the Screw and dismantle the Cover.
- Feed the Cable into the Cover during this operation.

- Cover
- Screw
- Cable gland
- Cable
- Remove the cable shoe Nut and the Earth connection.
- Disconnect the Air hose.
- Remove the Screw and pull out the unit with the Insulator housing and the Element.

- Element
- Insulator housing
- Screw
- Nut
- Air hose
- Earth connection
- Remove the Nut and pull out the Element.
- Change the element.
- Check the Seal, the Seal, the Seal, the Insulator, and the Insulator. Change, if .
- Note the marking of the Element connection.
- Assemble in the reverse order.Note: If the LS-heater has been removed, align the heater. See Procedure on page .
- Make sure that there is no air leakage.

- Element
- Seal
- Insulator
- Seal
- Element connection
- Seal
- Insulator
- Nut
- O-ring
Basic Settings Longitudinal Seal
Cells containing hyphen (-) refers to a setting when the configuration exists, but no value is set.Cells with grey background refer to a setting in which the configuration does not exist.Italic text refers to a setting that has not been verified, but are based on verified settings from similar configurations.Designations /ml, /ml-H, /ml-H+, /pbl, /jl, /jl MF, /aqk and /lk indicate different packaging material specifications.The letters S and N indicate settings for temperature (°C) valid for the Strip side respectively for the Nonstrip side.| Valid for: CLC/C Duplex board |
| Bottom format | Board stiffness (mN) | Volume (ml) | Blanks length (mm) | Temperature (°C) |
| /ml | /ml-H | /ml-H+ | /pbl | /jl | /jl MF | /aqk | /lk | | | |
| S | N | S | N | S | N | S | N | S | N | S | N | S | N | S | N |
| Base | 475 | 1000 | 245 | | | 180 | 270 | - | - | - | - | | | | | | | | |
| Base | 475 | 750 | 210 | | | 190 | 260 | - | - | - | - | | | | | | | | |
| Base | 370 | 1000 | 245 | 200 | 220 | - | - | - | - | 220 | 230 | | | | | | | | |
| Base | 370 | 750 | 210 | 200 | 220 | - | - | - | - | 220 | 230 | | | | | | | | |
| Base | 370 | 500 | 155 | 200 | 220 | - | - | - | - | 220 | 230 | | | | | | | | |
| Midi | 260 | 500 | 200 | 180 | 250 | - | - | - | - | - | - | - | - | | | 200 | 250 | - | - |
| Midi | 260 | 400 | 173.3 | 170 | 240 | - | - | - | - | - | - | | | | | | | | |
| Midi | 260 | 330 | 150 | 170 | 240 | - | - | - | - | 190 | 260 | | | | | 200 | 250 | | |
| Midi | 260 | 300 | 140 | | | | | | | | | 190 | 300 | | | | | | |
| Midi | 260 | 250 | 130 | 170 | 240 | 180 | 260 | 180 | 260 | 190 | 260 | | | | | | | | |
| Midi | 260 | 200 | 108 | - | - | - | - | - | - | 180 | 260 | | | | | | | | |
| MiniV | 260 | 330 | 175 | 170 | 240 | - | - | - | - | 170 | 270 | | | | | | | | |
| MiniV | 260 | 250 | 142.5 | 170 | 240 | 180 | 260 | 180 | 260 | 190 | 260 | 200 | 310 | | | | | | |
| MiniV | 260 | 200 | 125 | 170 | 240 | 180 | 260 | 180 | 260 | 190 | 260 | 200 | 310 | | | | | | |
| Mini | 260 | 330 | 180 | 170 | 240 | - | - | - | - | 170 | 280 | | | | | | | | |
| Mini | 260 | 250 | 147.5 | 170 | 240 | 180 | 260 | 180 | 260 | 190 | 260 | 200 | 310 | | | | | 180 | 280 |
| Mini | 260 | 200 | 130 | 170 | 240 | - | - | - | - | 190 | 260 | 200 | 310 | 180(1) | 310(1) | | | | |
| Mini | 260 | 150 | 108 | | | | | | | 180 | 260 | | | | | | | | |
| Micro | 150 | 100 | 108 | | | | | | | 160 | 290 | | | | | | | | |
| (1) 150 mN board stiffness |
| Valid for: CLC/C Bleached board |
| Bottom format | Board stiffness (mN) | Volume (ml) | Blanks length (mm) | Temperature (°C) |
| /ml | /ml-H | /ml-H+ | /pbl | | | |
| S | N | S | N | S | N | S | N |
| Base | 475 | 1000 | 245 | | | - | - | - | - | - | - |
| Base | 475 | 750 | 210 | | | - | - | - | - | - | - |
| Base | 370 | 1000 | 245 | 180 | 270 | - | - | - | - | - | - |
| Base | 370 | 750 | 210 | 180 | 270 | - | - | - | - | - | - |
| Base | 370 | 500 | 155 | 180 | 250 | - | - | - | - | - | - |
| Midi | 260 | 500 | 200 | | | - | - | - | - | - | - |
| Midi | 260 | 330 | 150 | | | - | - | - | - | 190 | 290 |
| Midi | 260 | 250 | 130 | | | 180 | 290 | 180 | 290 | 180 | 290 |
| Midi | 260 | 200 | 108 | | | - | - | - | - | 130 | 250 |
| MiniV | 260 | 330 | 175 | | | - | - | - | - | - | - |
| MiniV | 260 | 250 | 142.5 | | | 180 | 290 | 180 | 290 | 190 | 290 |
| MiniV | 260 | 200 | 125 | | | 180 | 290 | 180 | 290 | 180 | 290 |
| Mini | 260 | 330 | 180 | | | | | | | | |
| Mini | 260 | 250 | 147.5 | | | 180 | 290 | 180 | 290 | 190 | 290 |
| Mini | 260 | 200 | 130 | | | 180 | 290 | 180 | 290 | 180 | 270 |
| Mini | 260 | 150 | 108 | | | | | | | 130 | 250 |
| Micro | 150 | 100 | 108 | | | | | | | 180 | 260 |
|
Bracket LS - Set Bracket
| Equipment Status | Program Step step zero |
| Special Equipment | Template Base TP No. 1477312 and 1477310 Template Midi TP No. 1502290 Template Mini TP No. 1521728 Template Micro TP No. 2605291 |
Burn hazard.Allow the heater to cool down before starting any work on it.The heater can be hot.
When performing this instruction on Festo machines, use the air service tool. See Air Service Tool Description.- Valid for: Mecman machineActivate valve T21K2118 for S1 and valve T21K2218 for S2.
- Use the templates to set distance A and distance B according to the table.
| Distance | Base | Midi | Mini | Micro |
| A (mm) | 79 | 64 | 56 | 46 |
| B (mm) | 72 | 64 | 56 | 46 |
- With the LS -heater in its top position, set the vertical position by aligning the Template or the Template against the Slide rail. Adjust with the Screw.
- Unlock the Screw.
- With the LS -heater in its top position, align and distribute the LS -heater against the Slide rail. Lock with the Screw.
- If Mecman sensor, position the Proximity switch as high up on the cylinder as possible.If Sick sensor place the top of the sensor 4.65 mm offset from the edge of the cylinder.
- Set the Throttle check valve and the Throttle check valve so that the cylinders move smoothly in both directions.

- Cooling body
- Slide rail
- Screw
- Piston rod head
- Throttle check valve
- Proximity switch
- Throttle check valve
- Screw
- Template
- Template
Conveyor - Basic Setting of Vertical Position - Folding Pipes
| Equipment Status | Program Step step zero |
| Special Equipment | Telescopic gauge Template 3541949-0101 |
- Remove the Slide rail.
- Loosen Screw and Screw.
- Use the Template to set the distances A and B
- Tighten the Screw and Screw. Remove the Template.
- Measure the distance C between the Carrier belt and the Folding Pipe, using a telescopic gauge. The distance C must be at least three mm.
| Base/Midi/Mini | Mini (TT Mini 200ml /jl Al CLC/C Duplex 260mN IC) | Micro |
| A | 77 ±0.5 mm | 79.0 ±0.5 mm | 79.0 ±0.5 mm |
| B | 77 ±0.5 mm | 77.0 ±0.5 mm | 77.5 ±0.5 mm |
| C | 3.0 +0.5/-0.0 mm | 3.0 +0.5/-0.0 mm | 3.0 +0.5/-0.0 mm |

- Slide rail
- Screw
- Carrier belt
- Folding Pipe
- Screw
- Template
- If the bottom sleeve size is still too small, see item Reference - Reference.
- Adjust on the Knob (maximum three on scale).
- Loosen the Screw and increase distance A from 77 mm to maximum 79 mm. Tighten the Screw.
- To keep the distance to the Carrier belt, adjust the settings for the Slide rail. See Procedure Conveyor - Basic Setting - Slide Rail.
- Measure the bottom sleeve size once more.

- Slide rail
- Screw
- Carrier belt
- Knob
Conveyor - Basic Setting of Vertical Position - Sleeve Rollers
| Equipment Status | Program Step step zero |
- Loosen the Allen screw which fixes the eccentric shaft at the rear end section of the shaft.
- Set the Dial at 1.5 by turning the Hand wheel.
- Tighten the Allen screw.

- Hand wheel
- Dial
- Allen screw
Conveyor - Basic Setting - Slide Rail
| Equipment Status | Program Step step zero |
| Special Equipment | Slide Rail TP No. 1480292-0000 (Base, Midi & Mini) Setting Template TP No. 2605313-0000 (Micro) |
- Make sure that the Handle is properly tightened.
- Loosen the Nut and push the Slide rail backwards until it is fully home in the Pin hole.
- Tighten the Nut.
- Basic set the guide bracket to the distance A with the Screw.

A (mm) = 6.0 ±0.1
- Nut
- Screw
- Handle
- Pin hole
- Slide rail
- Inch the Folding plate to its top position. Use a Ruler to centre the slide rail (11) to the Folding plate. See illustration below.
- Tighten the Screw slightly. Put a Feeler gauge between the slide rail (11) and the Carrier belt to set the distance B.
- Tighten the Screw to final torque.

B (mm) = 3.0 ±0.2

- Ruler
- Folding plate
- Screw
- Feeler gauge
- Carrier belt
- Slide rail
- Remove the Squeezer roller (Base only).
- Push the two Template into roller rows, as illustrated, or move a sleeve (largest volume) in position between the Roller row by turning the electrical motor wheel.Note: For Base, Midi, and Mini: Use the Mark in the end of the Template during aligning with the Slide rail.
- Centre the Slide rail vertically with the Screw and sideways by the Nut.
- Put the Squeezer roller (Base only) back.
- Template
- Roller row
- Slide rail
- Mark
- Nut
- Screw
- Squeezer roller
Conveyor - Basic Setting - Squeezer Roller
| Equipment Status | Program Step step zero |
- Loosen the Screw for the inner Squeezer roller.
- Move the inner squeezer roller to the distance C from the Beam. Tighten the Screw.
- Loosen the Screw of the outer squeezer roller.
- Move the squeezer roller to the distance C from the Beam and to a position along the machine that corresponds to the other squeezer roller.
- Inch a Sleeve through the conveyor and check that it reaches the outer and inner squeezer roller at the same time (A = B as illustrated). If not, re-position the outer squeezer roller according to item Reference and Reference.
- Use of Setting Template, secure 90 degrees orientation on Shaft relative Sleeve and both Shaft will be aligned to each other.
- Secure full contact between Setting Template and Arm For Wheels.

A = B
C (mm) = 1.0 to 1.5
- Squeezer roller
- Screw
- Beam
- Sleeve
- Setting Template
- Shaft
- Arm For Wheels
Sleeve Forming Unit (Sleeve Maker)
Sleeve Forming Unit - Check Size for Sleeve
| Special Equipment | TP No. 1469631-0200 Sleeve size meter TP No. 3446229-0100(Base) Sleeve size meter TP No. 3446200-0100(Midi) Sleeve size meter TP No. 3446224-0100(Mini) Sleeve splitter; Cutter and Guide TP No. 3446212-0100 |
Measure at least 20 sleeves. All of the sleeves must be within the tolerances stated in the following table.If a sleeve tester is not available, flatten out the sleeve and measure the outside width. | Measure | Base | Midi | Mini 150-250 | Mini 330 | MiniV 200-330 | Micro |
| Flat sleeve (mm) | Top (A) | 128.4 ±0.2 | 102.8 ±0.2 | 86.0 ±0.3 | 86.1 ±0.2 | 86.1 ±0.2 | 64.9 ±0.2 |
| Bottom (B) | 128.8 ±0.2 | 103.1 ±0.2 | 86.2 ±0.3 | 86.3 ±0.2 | 86.3 ±0.2 | 65.1 ±0.2 |
| Opened sleeve (mm) | Top (A) | 258.4 ±0.4 | 207.4 ±0.5 | 173.7±0.8 | 173.9±0.6 | 173.9±0.6 | N/A |
| Bottom (B) | 259.3 ±0.4 | 208.2 ±0.5 | 174.3 ±0.8 | 174.5 ±0.6 | 174.5 ±0.6 | N/A |
Sleeves Measured Flat (outside)

C = 5 (mm)
- Measuring line
- Bottom of sleeve
- Top of sleeve
Measure Opened Sleeves with Sleeve Size Meter
- Put the sleeve slitter along the longitudinal seal of the Sleeve.
- Press down the Cutter, and drag it along the guide until the Sleeve is opened.Note: The cut edge should be free from fringes and have a straight angle. If the edge is not straight, change the razor blade.Note: If needed, adjust the razor blade position in the Cutter. Make sure that the Cutter only cuts through the upper packaging material layer.
- Open the sleeve and bend the creases backward.

- Cutter
- Sleeve
- Fasten the sleeve size meter with a Screw clamp for easy operation.
- Connect the Air hose (middle hose) to a compressed air supply.
- Unlock the Knob on the sleeve size meter Dial indicator.
- Reset the Dial indicator to zero by pushing the Set button.
- Lock the Knob by pulling it out gently.

- Screw clamp
- Air hose
- Set button
- Dial indicator
- Knob
- Insert the opened Sleeve in the slot. Make sure that the longitudinal seal is placed by the Dent and that the edge of the material aligns to the anvil on the back of the sleeve meter, and to the left.

- Sleeve
- Dent
- Flip the pneumatic Valve on the sleeve size meter to flatten and lock the Sleeve.
- Gently release the Knob on the Dial indicator, and note the value shown on the Display.
- Add the value below to the value shown on the Display, and check the result in the table on page Reference.
- Value for Mini/MiniV: 170 mm
- Value for Midi: 200 mm
- Pull the Knob and lock it again.
- Flip the pneumatic Valve to release the Sleeve. Measure all the samples repeating items Reference to Reference.

- Sleeve
- Dial indicator
- Knob
- Valve
- Display

Sleeve size meter seen from the back
Sleeves Measured with Sleeve Tester
- Open the Sleeve Tester.
- Align the sleeve against the milled surface, LS should be turned downwards. Close the Sleeve Tester.
- The alignment of the top and the bottom of the sleeve against the Surface should be seen in the Hole.
- Measure with the Calipers distance A.Note: During the sleeve measurement, keep the Sleeve Tester pressed together with one hand.

A = Sleeve Size
- Sleeve Tester
- Hole
- Calipers
- Surface
Sleeve Forming Unit - Change Sleeve Rollers
| Equipment Status | Program Step step zero |
Disassembly
Remove the Nut of the Sleeve roller and remove the damaged roller with its shaft.Note: Take care of the Shim (Base only), if any, for later use.Assembly
- Press the first new Bearing on the Shaft.Note: Only apply pressure to the inner ring of the bearings.
- Press the Sleeve roller on the Bearing.
- Press the second new Bearing on the shaft and in the roller.
- Fit the Locking screw into the shaft.
- Check that the roller rotates easily.
- Fit the assembled sleeve roller on the bracket and tighten the Nut.Note: If the sleeve roller shaft has been fit with a shim before removal, the shaft must be refit with the same shim. For the Shim (Base only) and shim thicknesses, see the distances A, B, C and D on the illustration below.

A (mm) = 0.5
B (mm) = 1
C (mm) = 1.5
D (mm) = 1.5
- Nut
- Sleeve roller
- Shim (Base only)
- Locking screw
- Bearing
- Sleeve roller
- Bearing
- Shaft
- Squeezer roller (Base only)
Sleeve Size Guideline
This chapter is a guideline to adjusting the sleeve size. Some of the adjustments mentioned here are also available in other chapters, for example in 2.4.2-3 Conveyor - Basic Setting of Vertical Position - Folding Pipes, 2.4.3-4 Sleeve Forming Unit - Fine Adjust Top Size - Sleeve, and 2.4.3-5 Sleeve Forming Unit - Set Bottom and Top Size for Sleeve.General
There are different parameters that affect the sleeve size. In this guideline the focus is on the parameters with largest impact on the sleeve size. They are: creasing roller distance, distance between squeezer roller and conveyor belt, distances between folding pipe bracket and conveyor belt (rear and front) and dial.See descriptions and illustrations in Chapter Initial Settings.Initial Settings
Set the machine according to the values in the table.| Description | Chapter in MM | Value | Illustration |
| Creasing roller distanceNote: This value is valid for Midi 300 with Al foil. Other values are described in chapter 1.2.2.3-4 Creasing Unit – Set Creasing Roller. | 1.2.2.3-4 Creasing Unit – Set Creasing Roller | A = 0.9 mm |  |
| Distance conveyor belt and squeezer roller | 2.4.2-1 Conveyor - Set Squeezer Wheels | B = 2 mm |  |
| Distances between folding pipe bracket and conveyor belt | 2.4.2-3 Conveyor - Basic Setting of Vertical Position – Folding Pipes | A = 77 mmB = 77 mm |  |
| Dial | 2.4.2-4 Conveyor - Basic Setting of Vertical Position - Sleeve Rollers | n = 1.5 |  |
Slide Rail - Set
When changing any setting that affects the slide rail alignment, the slide rail must be reset.The slide rail setting has a large impact on the standard deviation.- Set slide rail. See 2.4.2-5 Conveyor - Basic Setting - Slide Rail.
Sleeve Size - Measure
- Measure sleeve size. See 2.4.3-1 Sleeve Forming Unit - Check Size for Sleeve.Note: Measure at least 20 sleeves.
Sleeve Size - Change
The following adjustments can be used for all formats and packaging materials. However, some adjustments have only been validated for Midi 300 with Al foil.| Wanted response | Change setting | Chapter in MM | Illustration |
| Smaller top size | Decrease belt to wheel distance. | 2.4.2-1 Conveyor - Set Squeezer Wheels |  |
| Larger top size | Increase belt to wheel distance. | 2.4.2-1 Conveyor - Set Squeezer Wheels |  |
| Smaller bottom size | Step 1. Decrease dial value until you reach desired bottom size (the top size also gets smaller in this step). | 2.4.2-4 Conveyor - Basic Setting of Vertical Position - Sleeve Rollers |  |
| Step 2. Increase belt to wheel distance to restore top size. | 2.4.2-1 Conveyor - Set Squeezer Wheels |  |
| Larger bottom size | Method 1: |
| Step 1. Increase dial value until you reach desired bottom size (the top size also gets larger in this step). | 2.4.2-4 Conveyor - Basic Setting of Vertical Position - Sleeve Rollers |  |
| Step 2. Decrease belt to wheel distance to restore top size. | 2.4.2-1 Conveyor - Set Squeezer Wheels |  |
| Method 2 |
| Step 1. Increase bracket back distance (A).until you reach desired bottom size (the top size also gets larger in this step). | 2.4.2-3 Conveyor - Basic Setting of Vertical Position – Folding Pipes |  |
| Step 2. Decrease belt to wheel distance to restore top size. | 2.4.2-1 Conveyor - Set Squeezer Wheels |  |
| Smaller top sizeSmaller bottom size | Decrease dial value. | 2.4.2-4 Conveyor - Basic Setting of Vertical Position - Sleeve Rollers |  |
| Larger top sizeLarger bottom size | Method 1: |
| Increase dial value. | 2.4.2-4 Conveyor - Basic Setting of Vertical Position - Sleeve Rollers |  |
| Method 2: |
| Increase bracket back distance (A). | 2.4.2-3 Conveyor - Basic Setting of Vertical Position – Folding Pipes |  |
| Method 3: |
| Decrease bracket front distance (B). | 2.4.2-3 Conveyor - Basic Setting of Vertical Position – Folding Pipes |  |
| Method 4: |
| Increase creasing roller distance. | 1.2.2.3-4 Creasing Unit – Set Creasing Roller |  |
| Smaller top sizeLarger bottom size | Method 1: |
| Step 1. Increase dial value until you reach desired bottom size (the top size also gets larger in this step). | 2.4.2-4 Conveyor - Basic Setting of Vertical Position - Sleeve Rollers |  |
| Step 2. Decrease belt to wheel distance until you reach desired top size. | 2.4.2-1 Conveyor - Set Squeezer Wheels |  |
| Method 2: |
| Step 1. Increase bracket back distance (A).until you reach desired bottom size (the top size also gets larger in this step). | 2.4.2-3 Conveyor - Basic Setting of Vertical Position – Folding Pipes |  |
| Step 2. Decrease belt to wheel distance until you reach desired top size. | 2.4.2-1 Conveyor - Set Squeezer Wheels |  |
| Larger top sizeSmaller bottom size | Step 1. Decrease dial value until you reach desired bottom size (the top size also gets smaller in this step). | 2.4.2-4 Conveyor - Basic Setting of Vertical Position - Sleeve Rollers |  |
| Step 2. Increase belt to wheel distance until you reach desired top size. | 2.4.2-1 Conveyor - Set Squeezer Wheels |  |
Graphical Representation of Responses
In the following graph, the setting value is represented by the vertical lines. The top sleeve size and the bottom sleeve size are represented by the horizontal lines.When moving the setting value left or right, the intersection between the setting value and the sleeve size follows the graphs.When moving from the Original setting value to the New setting value in the graph, the sleeve sizes move from Original bottom sleeve size to Smaller bottom size and Original top sleeve size to Smaller top size respectivelyThe following example shows what response is to be expected when lowering the parameter “Dial”.
- Original setting value
- New setting value
- Original bottom sleeve size
- Original top sleeve size
- Smaller bottom size
- Smaller top size
The graph Bracket Rear Minus Front describes the difference between the Bracket Rear value and the Bracket Front value. For example, if the Bracket Rear value is 79 and the Bracket Front value is 77, the setting value for Bracket Rear Minus Front will be 2.The following graphs are valid only after performing the initial settings. After any changing of the settings, the following graphs are no longer valid.Drive Unit - Check Bearings
| Equipment Status | Program Step step zero |
Note: Release the belt tension before carrying out the check.- Grasp the conveyor belt Sprocket and check for any play.
- If required, change the Bearing.

- Bearing
- Sprocket
Drive Unit - Set Carrier Belt
| Equipment Status | Program Step step zero |
| Special Equipment | Dynamometer, TP No. 74767-0102 |
Note: The carrier belt must be aligned before measuring.To achieve correct belt tension, apply a force of 25-35N to the centre point of the belt. If the deflection distance is 6.5mm, the belt has the correct tension.
The following method is a way to perform this setting.- Make sure that the belt does not slack.
- Measure the distance A between the beam and the carrier belt, at the Centre point.
- Calculate thickness C (subtract 6.5 from A).
- Find a feeler gauge with the calculated thickness C. Insert the feeler gauge between the carrier belt and the beam, at the Centre point.
- Use a dynamo metre to apply a force of 25N to 35N at the Centre point of the carrier belt. When applying the force, the belt must be in contact with the feeler gauge, but the feeler gauge must be easy to remove.
- If adjustment is necessary, loosen the Screw and the Lock nut on both sides of the carrier belt. For Base machines, the Screw must also be loosened.
- Use the Screw to adjust the carrier belt tension and then repeat item Reference to Reference.
- Make sure that the distance B is equal on both sides of the carrier belt.Note: The carrier belt must be aligned and must not wander.
- Tighten the Screw, Screw, and the Lock nut.

- Centre point
- Screw
- Lock nut
- Screw
- Screw
Drive Unit - Set Tension for Drive Belt
| Equipment Status | Program Step step zero |
| Special Equipment | Dynamometer TP No. 74767-0102 |
- Loosen the Nut.
- The distance A must be 5mm when the dynamometer reads 20 N. Adjust the belt tension by turning the eccentric shaft on the Belt tensioner.
- Tighten the Nut and verify that the set tension is correct.

A = 5 mm
F = 20 N
- Nut
- Belt tensioner
Drive Unit - Change Carrier Belt
| Equipment Status | Program Step step zero |
Note: For the illustration, see the next page.- To remove the Side Feeder, follow the instructions in Procedure Side Feeder - Remove.
- Valid for: Base Equipment only.Loosen the M6 bolts on the plate.Note: If the bolts are not loosened, the plate will bend and create unnecessary stops.
- Loosen the Screw.
- Loosen the lock nuts on the Screw.
- Adjust the Screw so that the Belt tensioner moves all the way in.
- Remove the Support.
- Remove the Screw on that side of the Fibre optical reader that is attached to the Side plate.
- Loosen the Nut for the drive belt tensioner.
- Loosen the Grub screw.
- Remove the Side plate, by removing the Screw.Note: Push out the Side plate by tightening a screw into the Hole.
- Remove the Drive belt and the squeezer and Counter wheel axles.
- Remove the Handle and the Slide rail.
- Loosen the Screw and lower the Guiding device.
- Remove the outer Squeezer roller.
- Remove the Carrier belt.
- Assemble in the reverse order.Note: Tension of carrier belt. See Procedure .Note: Tension of drive belt. See Procedure .Note: Setting of folding pipes. See Procedure .Note: Setting of squeezer roller. See Procedure .

- Carrier belt
- Squeezer roller
- Screw
- Fibre optical reader
- Screw
- Counter wheel
- Drive belt
- Support
- Nut
- Side plate
- Grub screw
- Screw
- Hole
- Handle
- Guiding device
- Slide rail
- Screw
- Screw
- Belt tensioner
- Screw (valid for base)
Drive Unit - Change Gear Worm Motor
| Equipment Status | Power must be turn OFF.
|
- Disconnect the electrical cables from the gear worm motor.
- Remove the Screw and the Wheel.
- Remove the Screw and the Housing.

- Screw
- Wheel
- Screw
- Housing
- Change the Gear worm motor and assemble in reversed order.

- Gear worm motor
Side Feeder - Set
| Equipment Status | Program Step step zero |
Basic Setting
- Make sure that the Pusher is at the right angle to the Blanks end position. Use a Set-square to check the angle (90° ±1°).
- If required, adjust by loosening the Screw and set the right angle.

A = 90o ±1o
- Pusher
- Blanks end position
- Set-square
- Screw
Final Setting
Inch the machine and set the length of the Rod, so that the distances A and B are the same (±0.5 mm), as illustrated.
- Rod
| C | D |
| Pusher in inner position | Pusher in outer position |
| S1 | S2 | S1 | S2 |
| MSP 880-1444 ±5º | MSP 60-640 ±5º | MSP 60-640 ±5º | MSP 880-1444 ±5º |
Side Feeder - Remove
| Equipment Status | Program Step Tank filling |
- Inch the machine to MSP 750 so the Carriage stand clear to be disassembled.
- Remove the Nut of the drive and detach the link arm.Note: Do not disconnect the pneumatic hoses unless the intention is to change the entire side feeder unit completely.
- Disconnect the pneumatic hoses.
Risk of damage to the equipment.Cover the pusher plungers, the mandrels, and the internal tools with a piece of card board or a piece of similar material before continuing this procedure.The pusher plungers, the mandrels, and the internal tools can be damaged if any other parts strike them when you remove the side feeder.
Remove the Screw.- Pull the side feeder out approximately 10 mm to clear it from the guide pins. Then move it forward to clear it from the Drive unit.

- Drive unit
- Carriage
- Nut
- Screw
Side Feeder - Overhaul
| Equipment Status | Program Step step zero |
- Remove the Screw and remove the Rod bracket.
- Remove the Screw and slide out the Carriage.
- Change the Bushing.
- Assemble in the reverse order.

- Rod bracket
- Screw
- Screw
- Bushing
- Carriage
- Rod
- Screw
Erector - Basic Set
| Equipment Status | Program Step Air on |
| Special Equipment | Template TP No. 977990-0301 (Base) Template TP No. 977990-0302 (Midi) Template TP No. 977990-0303 (Mini STD) Template TP No. 3442653-0000 (Mini V) Template TP No. 977990-0304 (Micro) |
| Consumables | Shim 987880 Shim 1309145 |
Prepare
- Remove the internal tools on one pair of mandrels. See Procedure Internal Tools - Remove in the LFU chapter.
- Put the Dummy on the mandrels.
- Thread the sleeves on a pair of mandrels, direct them downward, and close the tools. See Procedure LFU Remote Control - Handlein the LFU chapter.Step up to Step 3 Horizontal Force and then Activate Manually.Note: The pair of mandrels with dummies must be directed toward the forming plates.

- Dummy
- Remove the Screw, the Pusher rod, and the Pusher rod.
- Loosen the Screw, the Screw, the Screw, the Screw and jam nut, the Screw and jam nut, and the Screw.
- Loosen the Nut, the Nut, and the Nut.Note: Make sure that the erector unit presses against the Pin and the Pin.
- Tighten the Nut lightly.
- Manually tighten the Screw and jam nut and the Screw and jam nut until there is close contact with the erector unit and then tighten one more turn.
- Tighten the Nut, the Nut, and the Nut to 30Nm.
- Line up the erector plates with the mandrels according to Section Set Lower Forming Plates and Section Set Upper Forming Plates.

- Screw
- Screw
- Screw
- Screw and jam nut
- Screw and jam nut
- Pin
- Pin
- Nut
- Nut
- Nut
- Screw
- Pusher rod
- Pusher rod
- Screw
- Raise the upper forming plate halves (can be locked in raised position with the aid of an Allen key through the hole in one of the Locking block support and above the Erector frame).
- Remove the Shim from both ends from the lower forming plates. Put the Screw for the forming plates back and tighten them loosely.
- Put the Template (MIN-end directed to the mandrel) in each lower forming plate. The Template must stop in the bottom of the dummies for the internal tool.Note: The templates for MiniV only have a MIN-end and can not be turned.
- Hold one of the templates in position and measure the distance between the lower forming plate and the Template, in both the front and the rear end, with a feeler gauge. Repeat the procedure for the other lower forming plate.
- Remove the templates and put shims according to the thickness measured above. Tighten the Screw.
- Repeat items Reference to Reference, using both ends of the Template, MAX respectively MIN. If MAX does not fit, more, or less shims are necessary.Note: The templates for MiniV only have a MIN-end and can not be turned.

Y = Y-directionZ = Z-direction
- Locking block support
- Erector frame
- Shim
- Screw
- Template
- Check the parallelity between the Template (MAX-end directed toward the mandrel) by connecting them with the Frame. Push the templates toward the mandrel and hold them in position. The MAX-end must be parallel to the surfaces of the templates for internal tool.Note: The templates for MiniV only have a MIN-end and can not be turned.

C = MinD = MaxE = Parallelity - PassF = Parallelity - Fail
- Template
- Frame
- If the setting cannot be achieved, do the following adjustments.
- In the Y-direction: Loosen the Screw and move the forming plates in chosen direction.
- In Z -direction: If the difference between front and rear edges of the forming plates (against templates) exceeds ±0.1mm, adjust the Setting screw and the Setting screw. Do not forget to slack off the Nut, the Nut, and the Nut.
- In Z-direction: If there is a difference between left and right forming plate, measure the distance and add Shim under both ends of one forming plate. Tighten the Screw, the Screw, the Screw, and the Screw. Tighten the Nut, the Nut, and the Nut to 30Nm and check the parallellity once more.

Y = Y-directionZ = Z-direction
- Screw
- Setting screw
- Setting screw
- Nut
- Nut
- Nut
- Shim
- Screw
- Screw
- Screw
- Screw
- Loosen the Setting screw of the upper forming plates. Remove the Screw and remove the Shim under the Hinge. Check that there are two Shim under the Bracket as default (about 3.4mm).
- Raise the upper forming plate halves (can be locked in raised position with the aid of an Allen key through the hole in one of the Locking block support and above the erector Frame).
- Put the Template in the forming plates.
- Make sure that the upper forming plate presses against the Template and measure the required shim thickness between the Hinge and the upper forming plate. Choose a shim 0.1mm thinner than the measured value. Put the shims under the Hinge and tighten the Screw.
- Check once more against the Template.
- Repeat the setting procedure for the other upper forming plate.

Y = Y-directionZ = Z-direction
- Setting screw
- Screw
- Shim
- Hinge
- Shim
- Bracket
- Locking block support
- Frame
- Template
- Adjust the Setting screw so that they press against the erector Frame. If any further minor adjustment is required in the Z-direction at the front end, adjust with the Setting screw.
- The upper forming plates must press lightly against the templates in both ends. It should be easy to move the templates backward and forward using just a little force.
- Measure the distance in the front end (in Y-direction) between the Template and the upper forming plates. Divide the distance by using the Setting screw so that the templates centre in the forming plates.
- Remove the dummies and put the internal tools back on the mandrels.
- Set the pusher, see Procedure Pusher - Set Overtravel, where applicable.

Y = Y-directionZ = Z-direction
- Setting screw
- Frame
- Template
- Setting screw
Setting of Support Plate (Micro Only)
Use shim for setting of the support plate. - Centre the support plate to the forming plate to set the distance A.

A = 38 mm
Erector - Set Photocell Unit
| Equipment Status | Program Step |
- Place for example a ruler across the forming plate on top of the Holder and the Holder.
- Set the holders to the distance A, see the table below.Note: This setting is valid for both forming plates.Note: In continuous production the beam will be broken when the sleeve passes through the forming plate.
| Format | Distance A (mm) |
| Base and Midi | 21 ±0.5 |
| Base GoldeckBase Orinoco | 30 ±0.5 |
| Mini and Micro | 16 ±0.5 |
Note: For the openings Base Goldeck and Base Orinoco the holders TP No. 2880798 and TP No. 2880799 must be used. 
Top left: The illustration shows standard holder for all bottom formatsTop right: The illustration shows holder for Base Goldeck and Base Orinoco
- Holder
- Holder
Erector - Remove
| Equipment Status | Program Step |
- Remove the pusher, see Procedure Pusher - Remove on page Pusher - Remove (the bracket position on the link arm must be marked).
- Remove the Screw, the Screw, and the Screw.
- Remove the Screw, the Screw, the Screw, the Infeed mandrel detector, the Infeed mandrel detector, and the Infeed mandrel detector.
- Disconnect the hoses from the Cylinder.
- Remove the Nut, the Nut, and the Nut.
- Remove the erector unit from the machine frame.

- Cylinder
- Screw
- Screw
- Screw
- Infeed mandrel detector
- Screw
- Infeed mandrel detector
- Screw
- Screw
- Infeed mandrel detector
- Nut
- Nut
- Nut
Distributor Arm - Remove
| Equipment Status | Program Step |
- Remove the Screw.
- Loosen the Nut to slacken the belt tension.
- Disconnect the hoses at the Hose connection.
- Loosen the Screw and slip the Distributor arm off the axle pin.

- Nut
- Timing belt
- Screw
- Screw
- Distributor arm
- Hose connection
Distributor Arm - Assemble
| Equipment Status | Program Step |
| Special Equipment | Dynamo meter TP No. 74767-102 |
- Assemble in the reverse order to previous instruction, see Procedure Distributor Arm - Remove.
- Adjust tension of the Timing Belt by turning the Eccentric shaft to F = 50 N / 5.0 mm according to illustration below.
- Tighten the Nut and check that the belt tension still is correct.
- Nut
- Timing Belt
- Screw
- Screw
- Distributor arm
- Hose connection
- Eccentric shaft
Distributor Drive - Check
| Equipment Status | Program Step |
- Check that the edges of the Timing belt are not worn or frayed, and that the belt runs (is guided) correctly over the pulleys.
- In case of fault, change the belt, see Procedure Distributor Drive - Change Timing belt on page Distributor Drive - Change Timing belt.
- Check that the Gear wheel not are worn or damaged.
- Check that the Ball bearing not have any excessive play.
- Remove the Screw and check that the Distributor arm move smoothly. Lift the distributor arms to their top position and drop them; they must now fall down to their lower position by their own weight.
- Assemble and tighten the Screw.

- Timing belt
- Gear wheel
- Ball bearing
- Screw
- Distributor arm
Distributor Drive - Set Timing Belt
| Equipment Status | Program Step tank filling |
The side feeder must be preset according to the instructions in Procedure Side Feeder - Set on page Side Feeder - Set.- Inch the machine to MSP 0 - 388 (the rack is then at end position toward side 1).
- Step the machine down to step zero.
- Remove the screws of the Clamp element and the Clamp element so that the shafts can move freely.Note: To spread open the two halves of the clamping unit, use two of the screws from the clamping unit.

- Clamp element
- Clamp element
- Drive belt
- Belt tensioner
- Move the Distributor arm and set the distance B. See the table below.
| Distance | Base (mm) | Midi (mm) | Mini (mm) | Micro (mm) |
| B | 26 ±0.2 | 45 ±0.2 | 42 ±0.2 | 46 ±0.2 |
| C | 1.5 ±0.1 | 1.5 ±0.1 | 1.5 ±0.1 | 1.5 ±0.1 |
- Tighten the screws of the Clamp element and the Clamp element to a torque of 17 Nm, see earlier illustration.
- Loosen the Screw.
- Put a Steel ruler on the upper machined surface of the Gripping device. Turn the Pulley so that the steel ruler matches centre of the top plate, see below.
- Tighten the Screw and check again after tightening.
- Set the distance C between the Gripping device with a piston rod and a Rod end. Set the distance when the grippers are in the closed position. See distances C in the table above. Check that the gripping device does not press the crease of the package sleeve.

- Distributor arm
- Screw
- Gripping device
- Rod end
- Steel ruler
- Pulley
Distributor Drive - Set Belt Tension
| Equipment Status | Program Step |
| Special Equipment | Dynamometer TP No. 74767-102 |
Set the belt tension with the Belt tensioner and check the belt slack E when the dynamo meter reads 20 N.
E = 7 mm
F = 20 N
- Belt tensioner
Distributor Drive - Change Sliding Strip
| Equipment Status | Program Step |
- Remove the screws from the Sliding strip.
- Change the Sliding strip.Note: If possible, turn the Sliding strip to a new wear surfaces.
- Assemble in the reverse order.Note: When mounting the new sliding strip press it up against the rack.

- Distributor
- Sliding strip
Distributor Drive - Change
| Equipment Status | Program Step |
- Change the Bushing and the Bushing.
- Change the Slide strip, see Procedure Distributor Drive - Change Sliding Strip on page Distributor Drive - Change Sliding Strip.
- Change the Gear wheel. Make sure the distance between the gear wheel and the bearing cap is at least 0.2 mm.
- Change the Ball bearing.
- If the seal is damaged or worn, change the Cover.
- Assemble in the reverse order and set the timing.Note: When the shafts (including ball bearings) are fitted to the erector, make sure that the Ball bearing are mounted tightly against the Pulley and the Pulley, respectively the Oil seal (cover). Otherwise there is a risk for axial movement when the machine goes in production. If a double-check is necessary, dismantle the Pulley and the Pulley or the Oil seal (cover), the distance between the edge of the mounting to the ball bearing must be 3.0 ±0.1 mm.

- Ball bearing
- Bushing
- Slide strip
- Bushing
- Gear wheel
- Cover
- Ring
- Spring washer
- Pulley
- Pulley
- Oil seal (cover)
Pusher - Check
| Equipment Status | Program Step |
- Check for cracks or wear in the Contact surface. If required, change the Pusher piston and check the overtravel of the pusher, see Procedure Pusher - Set Overtravel on page Pusher - Set Overtravel.
- Check the Pusher piston surfaces for even wear. If one of the ends shows signs of excessive wear, make sure the pusher pistons are set correctly, see Procedure Erector - Basic Set on page Erector - Basic Set. The forming plates have to be aligned with the mandrels. See Procedure Pusher - Align on page Pusher - Align. The Linear guide have to be in line with the forming plates.Note: If the previous instructions do not permit the Pusher piston to rest evenly and firmly in the forming plate, continue with the following.
- Check the Pusher rod and make sure that they are straight. This can be done by using a ruler or preferably on a diabase table.Note: Valid for Micro: it is also very important that the Pusher piston support is straight and in line with the Pusher rod.

Top left: Valid only for Micro
- Contact surface
- Pusher piston
- Pusher rod
- Linear guide
- Pusher piston support
- Make sure the pusher piston slides effortless against the piston support. To check this, put the pusher piston in place using the bolts. Measure the distance A between the pusher piston and the piston support.

A (mm) = 0 -0/+0.4
- Mount the Pusher rod complete with the Pusher piston and the Spring on the Linear sliding unit using the screws but leaving out the Front end shim and the Back end shim. Measure the distance B between the Pusher piston in its front end and in its back end. The distance in the front end should be equal to or max. 0.2 mm, less than the distance in the back end. If this is not the case, the Pusher rod needs to be bent in the front end to achieve the correct distances described above.
- Remove the screws and put the Front end shim and the Back end shim equal to the distance measured between the Pusher piston and the forming plate. Add approximately 0.2 mm to the shims in the Front end shim against the forming plate.

- Pusher piston
- Pusher rod
- Front end shim
- Back end shim
- Spring
- Linear sliding unit
- Check the Pusher piston. It will now rest firmly against the forming plate and evenly between the front end and the back end. Slightly pull the Pusher piston in its front end away from the forming plate and let it spring back. It should snap back and rest firmly to the surface of the forming plate.
- Check that the Rod are clean and free from paper/plastic residue.
- Check the Rod and the Ball bushing for excessive wear.

- Pusher piston
- Rod
- Ball bushing
Pusher - Set Overtravel
| Equipment Status | Program Step step zero |
- Make sure that the basic setting is performed. See Procedure Pusher - Set.
- Set the overtravel (MSP 755 - 800) to distance A by adjusting the Link head. If necessary, adjust the Link arm to obtain the overtravel by loosening the Screw. Measuring the overtravel becomes easier if Overtravel mark are made on the Rod.

A = 1 mm to 1.5 mm
- Link head
- Link arm
- Screw
- Rod
- Overtravel mark
- Move the pusher to the rear end position, MSP 1393 - 240, by inching the machine.
- Set distance B by adjusting the Screw to obtain the distance at the rear end position, MSP 1393 - 240.
- Tighten the Screw.
- Secure the adjusted link heads with their lock nuts.
- Check distance B again.

B = 1.0 mm to 2.0 mm
- Screw
Pusher - Align
| Equipment Status | Program Step |
| Special Equipment | 1567930-0100 which contains: Box TP No. 90459-4569 Indicator TP No. 90459-4570 Stand TP No. 90459-4571 Magnet Bracket TP No. 1601144 |
- Raise the upper forming plate halves. They can be locked in raised position, with aid of an allen key through the hole in one of the locking block support and above the erector frame.
- Disconnect the link arm by disconnecting the Safety clutch on the Carriage.
- Remove the Stop arm, the Screw, and the Pusher piston.

- Pusher Rod
- Indicator
- Forming plate
- Stop arm
- Pusher piston
- Screw
- Carriage
- Safety clutch
- Place the Indicator with the magnetic stand on top of the upper Pusher Rod.
- Slide the pusher carriage (with the Indicator ) backward and forward in the Forming plate. Check aligning in both bottom and side. Maximum allowed deviation is 0.1/100mm.Note: Press on the Carriage during sliding to not affect the indicator. See arrow in illustration, previous page.Note: Make sure that the Indicator does not collide with the upper forming plate and affect the measuring.
- Adjust the height by loosen the Screw, the Screw, and the Screw. Move thereafter the Cantilever up or down.
- Tighten the Screw, the Screw, and the Screw.
- Adjust in side by loosen the Screw and the Screw, move thereafter the Steering.
- Tighten the Screw and the Screw.
- Assemble the Pusher piston and the Stop arm, see previous page.
- Connect the screw for the Safety clutch, see previous page.

- Screw
- Steering
- Screw
- Screw
- Cantilever
- Screw
Pusher - Lubricate
| Equipment Status | Program Step step zero |
| Special Equipment | Grease gun: TP No. 950926-0000 |
| Consumables | Grease: TP No. 344407-0000 |
Use a Grease gun to lubricate the four Lubrication point.Note: Two strokes with grease is enough. Too much grease can damage the seals. Remove surplus lubrication.
- Grease gun
- Lubrication point
Pusher - Remove
| Equipment Status | Program Step |
Note: Before removing the pusher, make sure that it is in the rear end position.- Mark the position of the Bracket on the link arm with a marking pen.
- Remove the Screw that holds the bracket to the link arm.
- Remove the Screw, the Screw, the Screw, and the Screw.
- Remove the pusher unit from the bracket as follows:

- Safety clutch
- Screw
- Bracket
- Carriage
- Screw
- Screw
- Steering
- Screw
- Forming plate
- Screw
Pusher - Assemble
| Equipment Status | Program Step |
Assemble in the reverse order according to Procedure Pusher - Remove.Note: The bracket must be attached to the link arm according to mark.
- Safety clutch
- Screw
- Bracket
- Carriage
- Screw
- Screw
- Rod
- Screw
- Forming plate
- Screw
Pusher - Change Piston
| Equipment Status | Power must be turn OFF. Program Step Step Zero |
- Remove the Screw and the Piston.
- Discard the Screw and the Spring.

- Spring
- Piston
- Screw
- Install the new Piston with new Screw and Spring.Note: Some Piston are asymmetrical. Make sure to install the Piston in correct position. See the illustration.
- Set the Piston. See Procedure Pusher - Set Overtravel.
Valid for: Nallo
- Spring
- Piston
- Screw
Pusher - Set
| Equipment Status | Program Step step zero |
Note: The forming plate must be manually set. See Procedure on page .- Remove the Screw and disconnect the Link head.

- Link head
- Screw
- Loosen the Screw and align the Rod. See Procedure Pusher - Align on page Pusher - Align.
- Loosen the Screw and add or remove shims so that the pusher plungers press against the forming plate with force F.Note: There are four screws per D line. Make sure to loosen all 16 screws.
- Use a dynamometer to apply a force of 5 N to 10 N on the Rod. A streak of light should be visible between the plunger and the forming plate when the force is applied.Note: Carry out the check above at both ends of the travel for the pushers.

F = 5 N to 10 N
- Screw
- Screw
- Rod
- Slide the pusher up against the Mandrel and set all four plunger halves so that they touch the mandrel tops simultaneously. Carry out setting with the Rod and the Screw.
- Tighten the Screw.Note: There are four screws per D line. Make sure to tighten all 16 screws.
- Loosen the Screw.
- Put back the Link head and tighten the Screw.

- Link head
- Screw
- Screw
- Screw
- Rod
- Mandrel
Pusher - Link Arms Basic Set
| Equipment Status | Program Step step zero |
- Adjust distance A for the Link arm on the Link arm.
- Adjust distance B for the Link arm on the Gunlet screw.

A = nominally 171 mm
B= nominally 268 mm
- Link arm
- Link arm
- Gunlet screw
Erector Fingers - Check Ball Bushings
| Equipment Status | Program Step |
- Check that the Rod are clean and free of packaging material and plastic residue.
- Check the Rod for excessive wear.
- Check the Ball bushing for wear.

- Rod
- Ball bushing
Erector Fingers - Set
| Equipment Status | Program Step Tank filling |
| Special Equipment | Template Forming Tubes: TP No. 977990-0301 (BASE) Template Forming Tubes: TP No. 977990-0302 (MIDI) Template Forming Tubes: TP No. 977990-0303 (MINI) Template Forming Tubes: TP No. 977990-0304 (MICRO) |
| Consumables | Shim 1 Base TP No. 1261126 Shim 2 Base TP No. 1141122 |
This operation can be executed in two different ways. Before a resetting is done, perform a quick check to check if the resetting is necessary.Quick Check
- Inch the machine until the outer carriages have gone back from overtravel (adjustment MSP 200-514). (The overtravel is about 4mm).
- Step the machine down to step zero.
- Check the distances D and C. See the table below. Check also that the distance C is equal at both ends of the forming plate. If the distances are incorrect, loosen the Screw and set the distances. If necessary, set according to Method A (Using a Template) or Method B (Without Template).
| Distance | Base | Midi | Mini | Micro |
| C (mm) | 74.0 ±0.5 | 58.0 ±0.5 | 48.5 ±0.5 | 37.0 ±0.5 |
| D (mm) | 23.0 ±0.5 | 25.0 ±0.5* | 23.0 ±0.5* | 25.5 ±0.5 |

- Screw
Method A (Using a Template)
- Check if the machine is equipped with Bracket or Bracket.
- If the machine has Bracket, loosen the screws and make sure that the bracket is in its lower position.

- Bracket
- Bracket
- Raise the upper forming plate halves. The upper forming plate halves can be locked in raised position using an allen key through the hole in one of the Locking block support and above the Erector frame. Put the Template into the lower forming plates halves. Push the template forward, toward and around the top of the mandrels.
- Inch the machine so that the encoder reads MSP 144, which is maximum overtravel.

- Locking block support
- Erector frame
- Template
- Loosen the two Screw, between the Rack and the Lug. The screws are accessible, in setting position, through holes in the frame.
- Check and adjust the vertical position of the Erector finger in the template grooves. Place the shims if necessary: The Shim 1 for outer carriages and the Shim 2 for inner carriages.
- Move the carriages relative the Rack so that the Erector finger reaches bottom of the template grooves.
- Tighten the Screw between the racks and the lugs. Check the position of the erector fingers and the indirectly driven carriages (strokes of the carriages are to be 200mm and 26mm, respectively).

- Screw
- Shim 2
- Shim 1
- Rack
- Erector finger
- Lug
- Make sure that the packaging material is in full contact with the pusher pistons on all sides. If the packaging material is deformed, use a feeler gauge between the template and the erector fingers to fine adjust the C measurement. The wanted state is illustrated in the middle example.Note: the C measurement is dependent on the sleeve size. Smaller sleeves need a lower C measurement. bigger sleeves need a larger C measurement.
- Run the machine and check that the Lid splice, from tools on the lid, lines up with the Packaging material crease. If deviation, remove the same thickness of the Shim 1 as the deviation, from one erector finger, and add the same thickness, under the other erector finger (Example: 0.5mm deviation = remove 0.5mm shims from one erector finger and add 0.5mm under the other). Run the machine and check again.Note: When changing the shims under the erector fingers, make sure that they never crash downwards or upwards into the forming plates.Note: Make sure that the Bracket does not collide with the Forming plate. There must be a clearance between the Bracket and the Forming plate, see arrow in illustration.

- Shim 1
- Lid splice
- Packaging material crease
- Bracket
- Forming plate
- If the machine is equipped with the Bracket, set the distance E by adjusting the Bracket.
- Tighten the Screw.

E = 0.5 ±0.1 mm
- Bracket
- Erector finger
- Screw
Method B (Without Template)
- Check if the machine is equipped with Bracket or Bracket.
- If the machine has Bracket, loosen the screws and make sure that the bracket is in its lower position.

- Bracket
- Bracket
- Put a sleeve in the forming plate.
- Inch the machine until outer carriages have gone back from overtravel (adjustment MSP 200-513). (The overtravel is about 4mm)
- Loosen the Screw.
- Set the erector carriages so that the sleeves are correctly shaped and supported by erector fingers, before they are sided onto the mandrels.
- Tighten the Screw.

- Screw
- Shim 2
- Shim 1
- Rack
- Erector finger
- Lug
- Locking block support
- Erector frame
- Run the machine and check that Lid splice, from the tools on lid, lines up with the Packaging material crease. If deviation, remove the same thickness of the Shim 1 as the deviation, from one erector finger, and add the same thickness, under the other erector finger. (Example: 0.5mm deviation = remove 0.5mm shims from one erector finger and add 0.5mm under the other.) Run the machine and check again.Note: When changing the shims under the erector fingers, make sure that they never crash downwards or upwards into the forming plates.Note: Make sure that the Bracket, not collides against the Forming plate. There must be a clearance between the Bracket, and the Forming plate, see arrow in illustration.

- Shim 1
- Lid splice
- Packaging material crease
- Bracket
- Forming plate
- If the machine is equipped with the Bracket, set the distance E by adjusting the Bracket.
- Tighten the Screw.

E = 0.5 ±0.1 mm
- Bracket
- Erector finger
- Screw
Erector Fingers - Set Retaining Ring
| Equipment Status | Program Step |
Set the distance A between the Carriage with the Retaining ring, as illustrated.| Format | Distance A (mm) |
| Base, Midi and Mini | A = 187 ±1.0 |
| Micro | A = 163 ±1.0 |

- Carriage
- Shaft
- Retaining ring
Erector Fingers - Set Strut Bearings
| Equipment Status | Program Step |
- Adjust the Rack and the Rack so that they are in perfect alignment, vertically as well as horizontally.
- Position the Strut bearing, the Strut bearing, the Strut bearing, the Strut bearing, and the Strut bearing so that there is play, that is not twisted so that they jam the racks. (Use a feeler gauge in assembly to guide the bearings to their correct places.)

- Rack
- Rack
- Strut bearing
- Strut bearing
- Strut bearing
- Strut bearing
- Strut bearing
- Inch the machine so that the Carriage is in its outer extreme position and the Arm is above the Erector strip.
- Loosen the Screw.
- Slide the Strut bearing towards the Rack so far that there is the distance A between the Rack and the Strut bearing.
- Tighten the Screw.

A (mm) = 0.1 to 0.2
- Rack
- Strut bearing
- Gear wheel
- Screw
- Arm
- Carriage
- Erector strip
Erector Fingers - Lubricate Carriages
| Equipment Status | Program Step tank filling |
| Special Equipment | Grease gun: TP No. 950926-0000 |
| Consumables | Grease: TP No. 344407-0000 Anti-seize: TP No. 344417-0000 or 344418-0000 |
Note: Inch the filling machine to correct position to be able to reach all lubrication points.Use a Grease gun and grease with TP No. 344407-0000 to lubricate the Lubrication point and the Lubrication point.The Lubrication point are accessible when the carriages are in their outer position and the Lubrication point are accessible in their inner position.Note: Remove surplus lubrication.
- Grease gun
- Lubrication point
- Lubrication point
Lubricate Coupling Points Between Racks and Carriages
Use anti-seize TP No. 344417-0000 or 344418-0000 to lubricate the three Coupling point and the Coupling point (one side shown in illustration) between the racks and the erector carriages.Note: Remove surplus lubrication.
- Coupling point
- Coupling point
Lubricate Gear Wheel
Use grease TP No. 344407-0000 to lubricate the gear wheel:Note: Remove surplus lubrication.
- Contact surface
- Hole
Overview
* Plastic pipe, see also “Granulate Hopper”, in Chapter Filling SectionFunctional Description
The cooling water system consists of three circuits: ice water from the customer cooling system, the internal cooling system and a separate internal cooling system for the LFU. It is important to follow the specifications in the IM to make the system function properly.Ice Water from the Customer Cooling System
Ice water is transported directly to the oil cooler in the Hydraulic unit O202 and the cooler in the Electrical cabinet O207. Ice water is also transported in the primary circuit in the Heat exchanger O203 and the Heat exchanger O212, in the two internal systems.The ice water used in the filling system is divided in two lines between S1 and S2. Each line has two units. In one unit, HEPA air cools the peroxide reducer, the tank breathing and the cleaning boxes. The other unit is in series with the first unit. It is an air cooler with HEPA air for the hygiene chamber.
- Electrical cabinet O207
- Heat exchanger O203
- Hydraulic unit O202
- Heat exchanger O212
The Internal Cooling System
One group for TT/3 1900, and one for TT/3 2000.- the ovens and guides in the ASU and Carton Section.
- the external and internal tools in the LFU.
- the guides and UV lamps in the Package Section.
The cooling water flow is regulated by the flow meterA30P4331 to the flow meterA72Q2212.The temperature is primarily regulated by an adjustable temperature regulating valve. The temperature regulating valve is sensitive to the temperature sensorA24B0202 of the outflow, on the secondary side of the heat exchanger. It regulates the flow of ice water on the primary side, depending on the measured temperature. It is of critical importance to keep the cooling water temperature constant for the internal and external tools. The temperature regulating valve has a pneumatically controlled on/off valve, pneumatic valveA24K0256/A66K0211, which is normally opened.Cooling Water System - Check Deionization Cartridge
| Equipment Status | Program Step |
- Check the Electrical connection for the deionization cartridge.Note: Make sure that the cable is properly connected to the sensing point.
- Check the TPOP for alarms - Deionization warning.
- If necessary change the deionization cartridge. See Procedure Cooling Water System - Change Deionization Cartridge on page Cooling Water System - Change Deionization Cartridge.
- To finish the production without the possibility to immediately change the deionization cartridge:
- Step the machine down to AIR ON. This will switch the alarm from yellow to blue, and another two hours of run time is possible.Note: In case of a yellow alarm the deionization cartridge must be changed. See Procedure on page .
- Electrical connection
- Deionization warning
Cooling Water System - Set Cooling Temperature
| Equipment Status | Program Step |
The Temperature regulator, regulates the temperature for the cooling water. To ensure that cooling water temperature not drops too much, the Valve actuator (F200), is built to shut down the cooling water outlet.The Valve actuator (F200) is normally open.The Valve actuator (F200) closes (= air pressure On), after that the temperature has dropped 1 °C from pre-set value.The temperature of the regulator is set to one degree Celsius higher than on the TPOP to make the regulator precede the value of the TPOP.
- Temperature regulator
- Air hose
- Valve actuator (F200)
- Set the cooling water temperature on the TPOP to 27 °C.
- Disconnect the Air hose from the Valve actuator (F200).Note: If the Air hose is connected, the PLC will try to close the Valve actuator (F200), when the temperature is falling, and therefore make it impossible to adjust the temperature on the Temperature regulator.
- When both lines are in production, adjust the Temperature regulator, until the temperature is stable, 28 °C.
- Connect the Air hose to the Valve actuator (F200).

- Temperature regulator
- Air hose
- Valve actuator (F200)
- On the pneumatic panel, alternate between pressing and releasing the valve A66K0211.
- In the same time, put your hand on the Valve actuator (A24K0256) and feel the movement in the valve, fine tune the movement to be smooth by adjusting the Knob on the Throttle.

- Valve actuator (A24K0256)
- Knob
- Throttle
Cooling Water System - Fill Water Tank
| Equipment Status | Program Step |
- Open the Valve and fill the Cooling water tank. The refilling goes through the Filter, to the Cooling water tank.Note: If the Filter has been taken apart, bleed on the Button.
- Close the Valve.Note: Make sure that the Valve is open to the Pump.
Below is shown how the water refilling schematics is done.
- Pump
- Filter
- Button
- Valve
- Cooling water tank
- Valve
Cooling Water System - Bleed
| Equipment Status | Program Step |
Note: The Pump must never be run dry, this will lead to a major damage on the pump.Note: Make sure that the Valve is open.- Open the Valve and fill the Cooling water tank, at the same time, bleed on the Button on top of the Filter.
- Close the Valve, when the level is in the upper part of the Cooling water tank.
- Remove the Plug on the Pump, wait for the water to flow, put back the Plug.
- Check the level in the water tank during this time, complementary filling of the Cooling water tank will be needed, by opening the Valve.
Below is also shown how the water refilling schematics is done.
- Pump
- Plug
- Filter
- Button
- Valve
- Cooling water tank
- Valve
Cooling Water System - Fill or Bleed Glycol System
| Equipment Status | Program Step step zero |
Note: Make sure that the Valve is open.The cooling water system uses a solution composed of 50% glycol (TP 351472-0025) and 50% water.- Fill the Expansion vessel (empty cooling water system) with totally 8 litres.
- Remove the Plug on the Pump.
- When the glycol water is flowing, put back the Plug.

- Pump
- Plug
- Expansion vessel
- Valve
Functional Description
The power generating part of the unit consists of a 7.5 kW Electrical motor and a variable displacement Pump. The maximum continuous flow is 26 l/min at 1450 r/min. The displacement is controlled by the consumption of oil so that the flow at every moment is just enough to maintain the set pressure. The maximum pressure is set to 160 bar and a sealed overflow valve is set to 210 bar and has a maximum flow of 28 l/minute. The pump is connected to a 70 litre stainless steel Tank. The tank contains of a Level glass, an analogue Temperature gauge, and a level sensor with two alarm levels. The first starts an audible alarm, the second stops the machine.
- Temperature gauge
- Level glass
- Tank
- Electrical motor
- Pump
As the maximum instantaneous flow consumption is considerably higher than 26 l/minute there is an Accumulator on the pressure side. When the instantaneous flow is higher than 26 l/minute the accumulator supports the flow. When the instantaneous flow is lower than 26 l/minute the accumulator is recharged until it reaches full pressure. The accumulator, which is a bladder type, has a volume of 10 litres and is pre-loaded on the gas side to 120 bar.The hydraulic power unit contains another flow circuit for filtration and cooling. This consists of a 15 l/minute pump powered by a 0.18 kW Electrical motor. The filtration and cooling circuit is on continuously as long as the hydraulic power unit is on. The flow passes through a Heat exchanger where the cooling agent is dairy ice water. A temperature sensor in the circuit, before the heat exchanger, controls (on or off) the ice water flow. After the heat exchanger there is a Filter including a filter guard. The guard activates an alarm if the filter is clogged and needs to be replaced.This extra pump circuit can also be used to fill up and to empty the tank with hydraulic oil. A special hose is included for this.The hydraulic power unit contains the pump and tank unit for the Central lubrication.
- Central lubrication
- Accumulator
- Filter
- Heat exchanger
- Electrical motor
Hydraulic Unit - Check Hoses and Connections
| Equipment Status | Program Step |
Visually check hoses and connections for leakage.Hydraulic Unit - Check Pressure Drop
| Equipment Status | Program Step |
When a safety door is opened while the hydraulic pump is running, the hydraulic pressure must rapidly drop to zero. This safety function is monitored by pressure switch A24B0204.Fault-finding
- During operation: Alarm and indication on the TPOP.
- No signal is received from pressure switch A24B0204.
- Action: Replace the pressure switch.
- Fault after stopping the machine: Alarm and indication on the TPOP.
- The pressure must drop below 1.5 MPa within 3 seconds of stopping.
- A signal is still being received from pressure switch A24B0204.
- Action: Check the door safety switch.
Checking
- Open one of the safety doors and check on the pressure gauge that the pressure drops rapidly to zero. A slight knock must be heard from the accumulator after roughly one second when the membrane hits the end section.
- If the hydraulic pressure is low with the safety door closed:
- Trace for possible electrical faults.
- Check the hydraulic pump.
Hydraulic Unit - Check Oil Quality
| Equipment Status | Program Step step ZERO |
| Special Equipment | Sampling valve TP No. 1590255-0000 |
| Consumables | Food Grade Hydraulic Oil: TP No. 1607001-0000 (valid from machine 63202/20067 or for machines with UK-3355833-0100) Hydraulic Oil: TP No. 344474-4603 (valid for machines up to 63202/20066, without UK-3355833-0100) |
Oil requirement
To avoid unnecessary and unplanned stops in the hydraulic system, it is important to always maintain a high oil quality. Tetra Pak suggests in this instruction a way to handle this.It is not always enough to change the oil within a specified period. Tetra Pak also recommends a test of the oil even if it has been recently changed. This is to make it possible to find faults as overheating and water impairing before it causes a breakdown. See instructions below.The oil must be tested due to particle contamination and water impairing. The oil must correspond to (or be better):- ISO 4406:1999, 19/16/13 or SAE AS 4059 (similar to older NAS 1638), class 7.
- Water impairing must be maximum 200 ppm (= 0.02%).
- If there is a larger amount of water in the oil, it is possible to detect it by the methods described in Check of oil quality. However the oil can contain up to 600 ppm (0.06%) water without it being noticeable for the eye. The only way to detect this is with an laboratory test.
Oil Test
To get an oil test performed, contact for example HYDAC (www.hydac.com) and order equipment to take the oil sample.Tetra Pak suggests the oil analyse PVM-MVA-WA 1279078, which provides you with the following analyses:1/ Microscope impurity analyse2/ Water content (K. Fisher) Coulomat3/ Particle countingWhen an oil sample is taken and sent to HYDAC, the “Oil Sampling Record “on the next page must be completed. The record is also delivered with the oil sample equipment.As a test an oil sample was sent to HYDAC by Tetra Pak.The answer from HYDAC is shown below.
- Microscope impurity analyse
- Water content
- Cleanliness class SAE AS 4059
- Cleanliness class ISO 4406:1999
Oil Check
Check: Drain some oil every six months and perform a check according to the flowchart below. About how to drain, see the following pages. For every other check (= once a year) send an oil sample for analyse.Note: If the oil turns out to be impaired, follow the instructions in , to find the fault and repair it.Check of Oil Quality
| Type of Check | Analyse Description | Action |
| Oil Status | Check the oil visually and compare the smell of the old oil with new oil of the same type and brand. If the old oil looks and smells like the new oil it is usually in good condition. | 1/ If the oil smells or looks bad, change oil. See Procedure Hydraulic Unit - Change Oil.2/ Run the machine for a month. Send thereafter an oil sample for analyse. |
| Overheated Oil | Overheated oil is dark (= brown) and smells burnt (= bad smell). | 1/ Try to find out why the hydraulic oil has been overheated, and make action to protect from further overheating.2/ Change oil. See Procedure Hydraulic Unit - Change Oil. |
| Water or Air Impairing in Oil | If the oil is “cloudy” (= white), it indicates that the oil contains a lot of water or air.Water DetectionTo find out if there is water in the oil use one (or both) of these methods:1/ Perform a “crackle test”: Pour a sample of the oil in a large spoon. Heat the spoon from the underside (by a cigarette lighter). If there is water in the oil it will start boiling and crackles.2/ Take an oil sample in a glass and let “rest” for a while. If there is water in the bottom, it is obvious what caused the impairing.Air DetectionIf there is no water according to items above, “whiteness” is due to air. Another sign for air in the oil is a not properly working system. With to much air mixed in, the oil system will “swing” and probably cause an odd behaviour in the LFU. There can also be cavitation noise (slam from the pump). | Whiteness due to water:Try to find out why the oil is impaired with water. Some causes are listed below:- A faulty heat exchanger.- Water has pierced into the tank during cleaning.- Condense.The oil must be changed to protect the system from unnecessary wear and corrosion. Do as follows:1/ Let the hydraulic unit “rest” for a while. Evacuate the water by draining the oil tank until oil comes out. See Procedure Hydraulic Unit - Change Oil.2/ Run the hydraulic unit.3/ Change oil. See Procedure Hydraulic Unit - Change Oil.Whiteness due to air: - Low oil level in tank - Fill it up.- Air leakage somewhere in the hydraulic system. Probably in the suction pipe for the hydraulic pump - Try to trace and repair. |
How to Drain for an Oil Sample
- Connect the Sampling valve to the Test point: A30K1229 (S1) or A30K2229 (S2).
- Start up the hydraulic unit on low pressure. See Procedure LFU Remote Control - Handle.
- Drain out approximately 0.5litres of oil, before filling up the bottle for the oil sample.Note: It is very important to drain at least 0.5litres. This is to clean the Sampling valve from foreign particles.
- Remove the Sampling valve from the Test point.

- Sampling valve
- Test point
Hydraulic Unit - Check Oil Accumulator Pressure
| Equipment Status | Program Step |
- Step up side 2 to program step tank filling.
- Check the Pressure gauge. The Pressure gauge should show a system pressure of 16 MPa (160 bar).
- Step down the machine one program step with the arrow button on the side 2 door panel while at the same time watching the Pressure gauge. The pressure will decrease and after a while it will temporarily drop all the way down to zero. Note the pressure just before the pressure drops down to zero.
- Make sure that the pressure just before the drop down to zero is above 11.0 MPa (110 bar). This pressure is approximately 1.0 MPa (10 bar) lower than the charging pressure of the accumulator that must be 12.0 MPa (120 bar).
- If required, pre-load the accumulator, see procedure Hydraulic Unit - Charge Accumulator using Pre-loading Equipment CGH-3000 on page Hydraulic Unit - Charge Accumulator using Pre-loading Equipment CGH-3000.

- Pressure gauge
Hydraulic Unit - Set Hydraulic Pump
| Equipment Status | Program Step |
Risk of damage to the equipment.When the hydraulic pump is changed due to failure, the maximum flow for the new hydraulic pump must be reduced.The factory flow setting for a new hydraulic pump, is to high for the application used in the TT/3, and can damage the
Electrical motor.
- Remove the Cap at the end of the Hydraulic pump.
- Loosen the Counter nut and then loosen the Adjusting screw until the tension is released.
- Slowly tighten the Adjusting screw again, until it catches and the tension is back.Note: Do not over-tighten the Adjusting screw.

- Electrical motor
- Hydraulic pump
- Cap
- Adjusting screw
- Counter nut
- From that position, tighten the Adjusting screw another four revolutions.
- Tighten the Counter nut.
- Assemble and tighten the Cap.
- Perform a setting of the pressure regulator, see Procedure Hydraulic Unit - Set Pressure Regulator on page Hydraulic Unit - Set Pressure Regulator.
Risk of damage to the equipment.Make sure that the cavity in the hydraulic pump is filled with oil before starting the hydraulic unit.The bearings in the hydraulic pump can be damaged if they are used without oil.
Before starting the hydraulic unit, make sure that the cavity in the Hydraulic pump is filled with oil. 
- Electrical motor
- Hydraulic pump
- Cap
- Adjusting screw
- Counter nut
Hydraulic Unit - Clean Oil Cooler for Cooling Water
| Equipment Status | Program Step |
- Close the valve for the cooling water.
- Blow air through the Oil cooler. Prevent any splashing of dirt and water.
- Open the valve for cooling water and check that the Oil cooler is tight.

- Oil cooler
Hydraulic Unit - Change Oil
| Equipment Status | Program Step step zero |
| Special Equipment | Hydraulic Hose: TP No. 1590537-0000 or 90458-1427 |
| Consumables | Food Grade Hydraulic Oil: TP No. 1607001-0000 (valid from machine 63202/20067 or for machines with UK-3355833-0100) Hydraulic Oil: TP No. 344474-4603 (valid for machines up to 63202/20066, without UK-3355833-0100) |
Drain
- Put the tube end of the Hydraulic hose in an oil drum. Note: The Hydraulic unit contains 63 litres oil.
- Connect the Hydraulic hose to the quick connection (pressure side).
- Make sure that the Manual valve is open. See illustration below.
- Press and hold down the Button for the circulation pump to start the circulation pump.
- Oil will now start to drain from the tank to the oil drum. The Button for the circulation pump must be actuated, otherwise the circulation pump stops.

- Hydraulic hose
- Hydraulic unit
- Button for the circulation pump
- Manual valve
- quick connection (pressure side)
Fill Up
- Put the Hydraulic hose in the oil.Note: The hydraulic unit contains 63 litres of oil.
Risk of damage to the equipment. Only fill the hydraulic system through the quick connection (3).If you fill the hydraulic system through any other means than the quick connection (3), the system can become polluted.
Connect the Hydraulic hose to the Quick connection (suction side). During filling, the oil will be filtered in the hydraulic unit.- Close the Manual valve.
- Press and hold the Button for circulation pump to start the circulation pump. Oil is now sucked from the oil drum to the tank with a speed of 15 l/min. The Button for circulation pump must be actuated, otherwise the circulation pump stops.
Risk of damage to the equipment.The tank needs a head space of air to be able to breath. Do not overfill above the
Max oil level arrow. The viscosity of the oil can cause a delay.
When the level is half way on the Level glass, stop and wait a few minutes to see the correct oil level. 
- Hydraulic hose
- Button for circulation pump
- Quick connection (suction side)
- Manual valve
- Level glass
- Max oil level arrow
Fault Finding
If there is a problem getting the oil into the tank, the reason can be a clogged up filter.- Remove the Cap and take out the Filter.
- Clean the Filter and assemble the Filter on the Filter house.Note: Try to find out why the Filter is clogged and solve the root cause. Do not only clean the filter.

- Filter house
- Filter
- Cap
Hydraulic Unit - Change Accumulator Bladder
| Equipment Status | Program Step |
| Special Equipment | Wrench Punching device (width 20-23mm, height200 mm, recommended to use hard plastic in one end). |
Remove
Note: A change of the accumulator bladder must only be performed by experienced hydraulic technicians.- Remove the accumulator, see procedure section Hydraulic Unit - Change Accumulator on page Hydraulic Unit - Change Accumulator and place it in a vice or similar.
- Bleed the gas pressure using the pre-loading equipment, see procedure Hydraulic Unit - Charge Accumulator using Pre-loading Equipment CGH-3000 on page Hydraulic Unit - Charge Accumulator using Pre-loading Equipment CGH-3000.
- Remove the Lock nut and the Spacer.Note: Use a wrench and a plastic hammer to punch the wrench if necessary.

- Lock nut
- Spacer
- Slide the Oil valve into the accumulator body. Reach into the opening and remove the O-ring and washer from the Oil valve.
- Remove the Anti-extrusion ring from the Oil valve, fold the Anti-extrusion ring and take it out.
- Remove the Oil valve.
- Loosen the Lock nut.
- Remove the Bladder.

- Oil valve
- Anti-extrusion ring
- Lock nut
- Bladder
Preparation
- Clean the interior of the accumulator body.
- Spray some hydraulic oil on the inside of the accumulator body. This to facilitate the insertion of the bladder.
- Remove the valve cap, sealing cap, lock nut, and the gas valve from the new bladder.
- Spray the outside of the bladder with some hydraulic oil.
Install
- Fold the Bladder and insert it into the accumulator body.Note: The Bladder must be completely taut and not twisted.
- Put the Lock nut loosely to prevent the Bladder from falling back into the body.
- Insert the Oil valve.
- Insert the Anti-extrusion ring into the body and onto the Oil valve.
- Pull out the Oil valve.
- Pre-charge the Bladder to 2bar to secure the oil valves position.
- Assembly the washer, O-ring, and support ring.Note: Use only new O-rings, (seal kit TP No 90459-2891).
- Insert Spacer and Lock nut. Tighten to a torque of 440Nm.
- Tighten Vent screw to a torque of 30Nm.

- Lock nut
- Spacer
- Oil valve
- Anti-extrusion ring
- Lock nut
- Bladder
- Vent screw
- Tighten the Lock nut to a torque of:
- Nut 7/8- 14 UNF: 80Nm
- Nut M50 x 1.5: 150Nm
- Insert the Gas valve. Tighten to a torque of 0.4±0.1Nm
- Screw on the valve cap and Sealing cap. Tighten the Sealing cap to a torque of 30Nm.
- If the accumulator is to be stored for future use, check the pre-charge pressure again and if necessary adjust to 2bar. Note: Let the accumulator keep the pre-charge pressure (2bar) during storage.
- If the accumulator is to be assembled on the machine again, see procedure section Hydraulic Unit - Change Accumulator on page Hydraulic Unit - Change Accumulator.

- Lock nut
- Gas valve
- valve cap
- Sealing cap
Hydraulic Unit - Charge Accumulator using Pre-loading Equipment CGH-3000
| Equipment Status | Program Step step zero |
| Special Equipment | Pre loading equipment TP No 996373-0100 |
Risk of personal injury.Only use nitrogen in the accumulator.Oxygen in the accumulator will cause an explosion with serious personal injuries.
Risk of personal injury.Make sure that the hydraulic pump is turned off before starting any work on the accumulator system.
Risk of damage to the equipment.Repairs can only be performed by the manufacturer.The accumulator is a pressure vessel, any welding or mechanical machining can weaken the pressure vessel.
Risk of damage to the equipment.Only use recommended spare parts from Tetra Pak.A non-recommended valve can damage the accumulator.
Risk of damage to the equipment.Only use nitrogen in the accumulator.The accumulator will corrode and its lifetime will be reduced if air is used in the accumulator.
General Information
Supplied test certificates must be carefully filled out. The system operator is responsible for proper operation of the accumulator for example regular checks.Bladder accumulators are pre-charged with nitrogen to about 0.2 MPa (2 bar) when supplied. They must be pre-charged to the pressure specified by the manufacturer of the machine prior to commissioning. See the name plate also.| Variant | Adaptor thread |
| 996373-0101 | W24.32x11/4” |
| 996373-0102 | G5/8”-ISO 228 |
| 996373-0103 | W21.8x1/14” |
| 996373-0104 | W42.51x1/14” |
| 996373-0105 | W21.8x1/14” |
| 996373-0106 | W22x1/14” or W23x1/14” |
| 996373-0107 | W23x1/14” |
| 996373-0108 | G1/2”-ISO 228 |
| 996373-0109 | M22x1.5 |
| 996373-0110 | G3/4”-ISO 228 |
Charge Accumulator
- Connect the hexagonal Check-valve housing to the nitrogen bottle. In some markets an Adaptor is used for connecting the nitrogen bottle. This adaptor is included in the pre-loading equipment kit and is manufactured especially for the market in question.
- Remove the Sealing cap and the Valve cap from the accumulator gas valve. For the TT/3 accumulator, with 5/8”-18 UNF thread the Adaptor must be used (included in the pre-loading equipment kit). Assemble the adaptor onto the Gas valve before continuing. Assemble the Swivel connector onto the adaptor. Hand-tighten sufficiently to prevent gas leakage.
- Turn the Handle bar to the right, opening the gas valve core in the accumulator.
- Open the valve on the nitrogen bottle slowly to allow the expanding bladder to close the Oil valve.
- Charge to 12.0 MPa (120 bar).Note: The pressure will drop slightly when the compressed gas cools down. Therefore, pre-charge to 15 - 20% above the desired pressure.
- Sealing cap
- Valve cap
- Gas valve
- Adaptor
- Check-valve housing
- Bleeder valve
- Handle bar
- Swivel connector
- Adaptor
- Oil valve
- Close the valve on the nitrogen bottle. Wait for approximately 10 minutes. Check the pre-charge pressure. If the pressure is too high, bleed gas through the Bleeder valve.
- Turn the Handle bar to the left. Remove the Swivel connector.
- Remove the Adaptor.
- A gas leak detector is included in the pre-loading equipment kit. Use this to check for leaks.
- Assemble the Valve cap and the Sealing cap.
- Remove the Check-valve housing.
Hydraulic Unit - Charge Accumulator using Pre-loading Equipment (VGU-250)
| Equipment Status | Program Step step ZERO |
| Special Equipment | Pre-loading equipment TP No: 996373-0100 |
Risk of personal injury. Only use nitrogen in the accumulator.Oxygen in the accumulator will cause an explosion with serious personal injuries.
Risk of personal injury. Make sure that the hydraulic pump is turned off before starting any work on the accumulator system.
Risk of damage to the equipment.Repairs can only be performed by the manufacturer.The accumulator is a pressure vessel, any welding or mechanical machining can weaken the pressure vessel.
Risk of damage to the equipment.Only use recommended spare parts from Tetra Pak.A non-recommended valve can damage the accumulator.
Risk of damage to the equipment.Only use nitrogen in the accumulator.The accumulator will corrode and its lifetime will be reduced if air is used in the accumulator.
- Attach the 250 bar Pressure gauge to the Valve house.

- Pressure gauge
- Valve house
- Attach the Adapter to the Valve house.
| Machine version | Adapter |
| TT/3 – 1800/1900/2000 | 7/8” UNF long variant |
| TT/3 – 1700 G2 | 7/8” UNF long variant |
| TT/3 – 1700 G1 | 7/8” UNF short variant or 5/8”-18UNF (depending on manufacturing year) |

- Valve house
- Adapter
- Attach the Hose to the Valve house.

- Valve house
- Hose
- Turn the Star knob fully to the left to avoid damaging the Gas valve.
- Make sure that the Bleed valve is fully closed.
- Remove the sealing cap and the valve cap from the accumulator Gas valve.
- Attach the Valve house to the accumulator Gas valve.
- Turn the Star knob to the right until the indicator starts to move.Turn the Star knob another full turn and the Pressure gauge shows the accumulators preload pressure.

- Valve house
- Hose
- Star knob
- Gas valve
- Bleed valve
Bleed- If the pressure is high, open the Bleed valve until the pressure reaches 120 bar. Close the Bleed valve several times during bleeding to be able to read the correct pressure on the Pressure gauge.

- Pressure gauge
- Bleed valve
Charge- Connect the Hose to the gas supply bottle.Connection to a gas supply bottle with W24.32x11/4” tread does not need an adaptor. Other treads need an adaptor according to the table below.
| Variant | Adaptor thread |
| 996373-0101 | W24.32x11/4” |
| 996373-0102 | G5/8”-ISO 228 |
| 996373-0103 | W21.8x1/14” |
| 996373-0104 | W42.51x1/14” |
| 996373-0105 | W21.8x1/14” |
| 996373-0106 | W22x1/14” or W23x1/14” |
| 996373-0107 | W23x1/14” |
| 996373-0108 | G1/2”-ISO 228 |
| 996373-0109 | M22x1.5 |
| 996373-0110 | G3/4”-ISO 228 |
- Open the gas supply bottle slowly and fill the system until the pressure reaches 120 bar. Close the valve on the gas supply bottle several times during filling to be able to read the correct pressure on the Pressure gauge. The pressure in the accumulators can only be read when the gas supply bottle valve is closed.Do not overcharge!
- Wait for approximately 10 minutes to allow the pressure to stabilise and check the pressure again. Fill or bleed if necessary.
- When correct pressure is reached, turn the Star knob to the left to close the accumulator.
- Make sure that the valve on the gas supply bottle is fully closed.
- Release the pressure in the filling equipment by opening the Bleed valve.
- When the filling equipment is depressurised, remove the gas filling equipment from the accumulator.
- Check the Gas valve on the accumulator for leakages with, for example, leak detection spray.
- Fit the sealing cap and the valve cap to the accumulator.

- Pressure gauge
- Star knob
- Bleed valve
Functional Description
The central lubrication system uses a piston pump driven with compressed air. In order to operate correctly the system must be free from air. The lubricant is fed from the central lubrication pump through the main line, distribution blocks and to the dosing valves in the dosing blocks. From here the lubricant is independently dosed with a set quantity, to each lubrication point in the system. The pump keeps the lubricant under pressure for a short while during each lubrication cycle. The system is then decompressed to a pressure of approximately 2-5 bar. The residual pressure is important since a too high pressure does not give any refilling of the dosing valves and if there is no residual pressure, air might enter the system.The lubrication cycle runs every 15 minutes. The first 40 seconds of the cycle the pump is pressurising the system. By 38-40 seconds of the lubrication cycle the pressure in the system is checked by means of the pressure switch in the front of the machine. From the 51 second to the end of the lubrication cycle it is checked that the pressure switch is not activated. Thus it is verified that the pressure switch is working and is not short circuted.The system can also be activated from the TPOP to run an intense lubrication cycle e.g. when bleeding the system. See Procedure Central Lubrication - Force Lubrication through TPOP.Central Lubrication Unit - Check
| Equipment Status | Program Step |
The pressure during the lubrication pulses must be 5-6 MPa (50-60 bar). The pressure is shown by the Pressure gauge. The residual pressure between pulses must be 0.2-0.5 MPa (2-5 bar).The Pressure switch is located in the machine front.In case of alarm for low lubrication pressure, check the system for leakage.
- Pressure gauge
- Pressure switch
Central Lubrication Unit - Fill Oil
| Equipment Status | Program Step step zero |
| Consumables | Food Grade Central Lubrication Oil: TP No. 1607010-0000 (valid from machine 63202/20067 or for machines with UK-3355833-0100) Central Lubrication Oil: TP No. 344472-3203 (valid for machines up to 63202/20066, without UK-3355833-0100) |
Manually
- Remove the Lid.
- Add oil to the oil tank. The level will be approximately 30 mm below the top lid. The tank holds 3 litres of oil.
- Put back the Lid.
With the Quick Connection/Automatically
- Connect the Quick coupling and add oil to the oil tank. The level will be approximately 30 mm below the top lid. The tank contains 3 litres of oil.

- Lid
- Quick coupling
Central Lubrication - Bleed
| Equipment Status | Program Step air on |
| Consumables | Food Grade Central Lubrication Oil: TP No. 1607010-0000 (valid from machine 63202/20067 or for machines with UK-3355833-0100) Central Lubrication Oil: TP No. 344472-3203 (valid for machines up to 63202/20066, without UK-3355833-0100) |
To ensure a good lubrication through the central lubrication system, it is important that the system is free of air.To ensure a good function the system must be bled:- after a break off of the lubrication system
- after change and/or overhaul of a unit
To eliminate air in the supply hoses, loosen a venting plug or the supply hose at the connection blocks according to illustrations below.
Carton Section - Bleed

Illustration is showing Carton Section
Package Section - Bleed

Illustration is showing Package Section
- Lubrication block, in Package Section frame side 1.
- Lubrication block, in Package Section frame side 1.
- Lubrication block, in Package Section frame side 2.
- Lubrication block, in Package Section frame side 2.
- Joint piece, in the machine front (in front of side 1).
- Lubrication block, in bottom sealing unit side 1 (remove cover plate of bottom sealing.)
- Lubrication block, in bottom sealing unit side 2 (remove cover plate of the bottom sealing.)
- Force lubrication either through TPOP or manually. See Procedures Central Lubrication - Force Lubrication through TPOP or Central Lubrication - Manual Force of Lubrication (Festo, Mecman).
- Tighten the venting plugs and the supply hoses.
- Repeat item Reference to make sure of complete elimination of air.Note: If required add oil to the tank. See Procedure on page .
Central Lubrication - Force Lubrication through TPOP
| Equipment Status | Program Step |
- Press Manoeuvre window.
- Press Supply.

- Manoeuvre window
- Supply
- Push button (arrow) to make intensive lubrication alternative available.
- Push the button to activate intensive lubrication. The intensive lubrication function activates 10 seconds of pressure and then a pause for 20 seconds. This is repeated in a cycle of 10 times and ends after 300 seconds or when the oil level is too low.
- Check for oil at lubrication points.
- Manually stop intensive lubrication by pressing the
Off button or step the machine down, on both sides, to step zero.
Central Lubrication - Manual Force of Lubrication (Festo, Mecman)
| Equipment Status | Program Step |
Valid for Festo- Locate Valve A66K0210.

- Valve A66K0210
- Remove the two Screw.
- Remove the Cover.

- Screw
- Cover
- Turn the Solenoid valve clockwise to activate the lubrication pump.
- Let the lubrication pump be activated until oil, free from air is discharged.
- Turn the Solenoid valve anti-clockwise to deactivate the lubrication pump.
- Install the Cover.

- Cover
- Solenoid valve
Valid for Mecman- Push the solenoid valve for the lubrication pump on the Pneumatic Unit 1, Ramp 1.
- Repeat until oil, free from air, is discharged.
Pneumatic System - Set Air Pressure (Festo, Mecman)
| Equipment Status | Program Step |
Valid for Festo- Set the air pressure for the LS ovens in positions 1 to 4 according to the table.
- Check and set the pressure on the manometers (5) and (6) according to the table.
| Position | Machine function | Air pressure kPa (bar) |
| 1 | LS oven S1 (stripside, T21K1253) | 100 (1.0) |
| 2 | LS oven S1 (non stripside, T21K1254) | 100 (1.0) |
| 3 | LS oven S2 (stripside, T21K2253) | 100 (1.0) |
| 4 | LS oven S2 (non stripside, T21K2254) | 100 (1.0) |
| 5 | LFU S1 (T21K0263) (XH, AD, SD and ASCM) | 350 (3.5) |
| LFU S1 (T21K0263) (XH with IC and Water) | 450 (4.5) |
| 6 | LFU S2 (T21K0258) (XH, AD, ASD and ASCM) | 350 (3.5) |
| LFU S2 (T21K0258) (XH with IC and AW) | 450 (4.5) |
Valid for Mecman- Set the air pressure for the LS ovens according to the table.
- Check and set the pressure on the manometer (5) according to the table.
| Position | Machine function | Air pressure kPa (bar) |
| 1 | LS oven S1 (stripside, T21K1253) | 100 (1.0) |
| 2 | LS oven S1 (non stripside, T21K1254) | 100 (1.0) |
| 3 | LS oven S2 (stripside, T21K2253) | 100 (1.0) |
| 4 | LS oven S2 (non stripside, T21K2254) | 100 (1.0) |
| 5 | LFU (T21K0258) (XH, AD, ASD, and ASCM) | 350 (3.5) |
| LFU (T21K0258) (XH with IC and AW) | 450 (4.5) |
Pneumatic System - Change Filter Insert (Festo, Mecman)
| Equipment Status | Program Step |
Valid for FestoThe Reservoir has a bayonet coupling.- Twist the Reservoir to the left.
- Pull the Reservoir down.Note: If the water level is above the automatic Drain valve, the drain valve is faulty and must be replaced.
- Clean the Reservoir with mild detergent and water.
- Unscrew and change the filter.
- Install the Reservoir.

- Reservoir
- Drain valve
Valid for Mecman- Press the Safety notch.
- Remove the filter insert and the Filter cup in one piece.
- Change the filter insert.
- Assemble the Filter cup in the reverse order.

- Safety notch
- Filter cup
Pneumatic System - Change Valve (Festo, Mecman)
| Equipment Status | Program Step |
Valid for Festo- Remove the two Screw.
- Remove the Cover.

- Screw
- Cover
- Remove the two Solenoid valve.
- Lift out the Valve.
- Install a new valve.
- Install the Cover.

- Screw
- Valve
- Cover
Valid for MecmanDepending on the application of the Valve, the Gasket is aligned in two different ways. See A respectively B.Note: When replacing a faulty valve, do as follows:- Dismantle the Cover, and note which position the Gasket is fitted in the Slot on the faulty Valve.Note: The lip of the Gasket is pointing to either no.1 or no.14.
- Check the new Valve to make sure that the Gasket is in the right position.

- Valve
- Cover
- Gasket
- Slot
Safety Air Valve - Set Soft Start
| Equipment Status | Program Step step zero |
General
The following table describes the functions performed by the Safety air valve.| Machine status | Phase | Function performed by the Safety air valve | Comment |
| Air on | 1 | The pneumatic system is exhausted of all air. | |
| 2 | The pneumatic system is pressurised to 50% of the incoming pressure | If the air pressure is impeded by leakage in the system, the Safety air valve will not continue to phase 3 |
| 3 | The pneumatic system is pressurised to 100% of the incoming pressure | |
| air off | Exhaust | The pneumatic system is quickly exhausted of all air | This function is also performed if an emergency stop is actuated, or if a door is opened |
The Manual open/close valve is normally in the open position.
- Manual open/close valve
- Safety air valve
Set Soft Start
The Adjustment screw must be set according to how large the pneumatic system to be pressurised is.To set the Adjustment screw to the standard setting, see the following instruction.- Turn the Adjustment screw as far as it will go in the right direction.
- Turn the Adjustment screw 4 full turns to the left.

- Manual open/close valve
- Safety air valve
- Pressure guard
- Adjustment screw
Functional Description
The package disinfection process in the TT/3 filling machine is based on vaporised hydrogen peroxide and UV-light. The hydrogen peroxide vapour condensates and forms a thin layer on the inside of the packaging material, and it has a strong germicidal effect when illuminated by the UV-lamp. When handling hydrogen peroxide take care to read the Section Hydrogen Peroxide in the Chapter ii Safety Precaution.The hydrogen peroxide system in the filling machine variant XH sprays vaporised hydrogen peroxide on the inside of the package just as it enters the hygiene chamber. The hydrogen peroxide (H2O2) used in the filling machine variant XH is diluted to a concentration of 3%.The hydrogen peroxide system in the filling machine variants AD, ADY, ASD, ASCM, and AW sprays vaporised hydrogen peroxide on the packaging material web before it is cut in to blanks. This is a pre-treatment of the inside of the packaging material. The sleeve is then formed and provided with a lid. The inside of the package is sprayed again just as it enters the hygiene chamber. The hydrogen peroxide (H2O2) used in the filling machine variants AD, ADY, ASD, ASCM, and AW is diluted to a concentration of 3%.- One tank (valid for XH) or two tanks (valid for AD, ASD, ASCM and AW).
- Two pumps (valid for XH) or four pumps (valid for AD, ASD, ASCM and AW). Two pumps for pre-treatment (valid for AD, ADY, ASD, ASCM, and AW) and two for package disinfection.
- One panel used for monitoring the flow to the pre-treatment evaporator (valid for AD, ADY, SD, ASCM, and Water). One panel used for monitoring the flow to the package disinfection evaporator.
- One pre-treatment evaporator and pressure switches (valid for AD, ADY, ASD, ASCM, and AW), and one package disinfection evaporator and pressure switches.
Valid for: Hygiene level XH
Valid for: Hygiene level XH with IC
Valid for: Hygiene level AD
Hydrogen peroxide is stored in the located in the ASU. The tank can easily be removed from the TT/3 filling machine as the tank has a . The tank has a built-in and is vented to atmosphere.The table shows the number of production hours before the tank(s) needs to be refilled, if both sides are in production at the same time. It also gives information about when the low-level alarm (a blue alarm on the TPOP) will go off, informing the operator how many minutes that are left before the tank is empty.| Description | Production hours | Low level alarm (min.) |
| Valid for: Hygiene level XHPackage disinfection | 16 | 60 |
| Valid for: Hygiene level ADPre-treatment | 32 | 120 |
| Valid for: Hygiene level ADPackage disinfection | 8 | 30 |
Valid for: Hygiene level AD
Not valid for: MSK H2O2 Tank Level Probe TT/3 3752157-0100A = Tank pre-treatment, B = Tank package disinfection
- Tank
- Quick-coupling
- Level sensor
Valid for: Hygiene level AD
Valid for: MSK H2O2 Tank Level Probe TT/3 3752157-0100A = Tank pretreatment, B = Tank package disinfection
- Tank
- Quick-coupling
- Level sensor
The tubing from the Quick-connection is divided into two, one for Side 1 and one for Side 2. Each side has an electrically driven peristaltic Pump. The rotation speed is controlled by an analogue signal of 0 to 4 VDC. The rotation speed of the pumps, and thus the hydrogen peroxide flows, are set by the operator from the TPOP. When installing a new pump or changing the tubing, the spring tension of the Spring loaded tension arm has to be set. This is done by turning a Setting screw. Adjusting the spring loaded tension arm to set the peroxide flow is not recommended. The hydrogen peroxide is pumped to the Spray body at the evaporator.
Valid for: Hygiene level ADA = Pump pre-treatment, B = Pump package disinfection, C = H2O2
- Quick-connection
- Pump
- Spring loaded tension arm
- Setting screw
- Spray body
The hydrogen peroxide flow and the air flow can be visually monitored on the Panel. It includes Filter and four flow meters. The hydrogen peroxide Flow meter, H2O2 are used for visually monitoring the H2O2 flows. The Flow meter, air are used for visually monitoring and adjusting the air flows. The panel includes an adjustable Regulator that regulates the system air pressure. From the panel the air is divided and distributed to the Spray body on Side 1 and Side 2.If the Heater is heated up without the air flow it will brake. The air comes from the Valve which is normally open. If there is a power failure or the coil to the valve has broken, the air will still flow through the spray bodies and heaters to protect them from damage.
Valid for: Hygiene level ADA = Panel pre-treatment, B = Panel package disinfection, C = Air, D = H2O2
- Panel
- Filter
- 2O2Flow meter, H
- Flow meter, air
- Regulator
- Spray body
- Heater
- Valve
At the Peroxide unit the peroxide and air flow is monitored by the Pressure switch, H2O2 and the Pressure switch, air. The Spray body has a built in needle that can be used to clear the nozzle if it has become clogged.Peroxide and air is atomised in the spray body and the mixture is then vaporised in the Heater. The temperature in the heater is controlled by a Thermocouple. Monitoring and adjusting of the temperature levels is done by the operator from the TPOP.The vaporised hydrogen peroxide air in the unit for pre-treatment is lead through the hose and out the peroxide spray nozzles in the Pre-treatment box. The vaporised hydrogen peroxide air in the unit for package disinfection is lead through pipe into the hygiene chamber and out through the peroxide Spray nozzle into the packages. The flow of hydrogen peroxide air mixture is constant.The spray unit contains a check valve to protect from uncontrolled drainage of hydrogen peroxide while the air is flowing through the spray body and the nozzles. The check valve is not adjustable.
Valid for: Hygiene level ADA = Evaporator pre-treatment, B = Evaporator package disinfection
- Peroxide unit
- 2O2Pressure switch, H
- Pressure switch, air
- Spray body
- Heater
- Thermocouple
- Pre-treatment box
- Spray nozzle
- Grease nipple
Peroxide Unit - Check Peroxide Level Guard
| Equipment Status | Program Step |
- Check the level guard of the peroxide tank.
| |
| Level OK: No alarm | Level low: Blue alarm |
 |
| |
| Empty tank: Yellow alarm | Disconnected: Yellow alarm |
 |
1 = Brown 12 = White 23 = Green 34 = Low5 = Empty
Peroxide Unit - Basic Setting
| Equipment Status | Program Step AIR ON |
Before further work is done on the system, set the following parts.- Set the pump. See procedure Peroxide Unit - Set Peroxide Pump Spring Tension.
- Set the air pressure switch. See procedure Peroxide Unit - Set Pressure Switch Air.
- Set the peroxide flow. See procedure Peroxide Unit - Basic Setting of the Peroxide Pump Flow.Note: Make sure to set the peroxide flow on the TPOP, not the tube.
- Set the pressure switch peroxide. See procedure Peroxide Unit - Set Pressure Switch Peroxide.
- Enable the package disinfection function at the TPOP.
- Step the machine up to heating.
- Check the Manometer for system pressure. For correct pressure, see the table. If necessary, adjust the pressure by turning the air Pressure regulator.
- Make sure that the Flow meter, air S1 and the Flow meter, air S2 are opened.
Valid for: Hygiene level ADLeft: Panel pretreatmentRight: Panel package disinfection
- Manometer
- Pressure regulator
- Flow meter, air S1
- Flow meter, air S2
- Knob
- Set the Flow meter, air S1 and the Flow meter, air S2 accordingly. Adjust at the Knob.
| Variant | Valid for: Hygiene level XH | Valid for: Hygiene level AD |
| Pretreatment | Package disinfection |
| System air pressure | 200 kPa (2.0 bar) | 200 kPa (2.0 bar) | 200 kPa (2.0 bar) |
| Air flow | 1600 l/h | 800 l/h | 1600 l/h |
Valid for: Hygiene level ADLeft: Panel pretreatmentRight: Panel package disinfection
- Manometer
- Pressure regulator
- Flow meter, air S1
- Flow meter, air S2
- Knob
- Check that air is coming from the Spray nozzle.
- Check the air pressure on the pressure switch Display. Make sure it is within the limits. See the table on page Reference.
- Adjust the heater temperatures on the TPOP. See the table.
- Check that the heater temperature is reached and stable.
Valid for: Hygiene level ADUpper left: Evaporator pretreatmentUpper right: Evaporator package disinfection
- Spray nozzle
- Display
Peroxide Unit - Set Pressure Switch Air
| Equipment Status | Program Step air on |
- Set the Pressure switch and the Pressure switch according to the table below.Note: Description for handling the display, see Procedure on page up to machine 63202/20132 on page from machine 63202/20133Valid for pressure transmitter 90459-1994 up to machine 63202/20132
| Pressure Switch Parameter | Valid for: Hygiene level XH | Valid for: Hygiene level AD |
| Pre-treatment | Package Disinfection |
| SP1: Upper limit value => | 800 mbar | 130 mbar | 800 mbar |
| rP1: Lower limit value => | 200 mbar | 60 mbar | 200 mbar |
| SP2 | 910* | 910* | 910* |
| rP2 | 900* | 900* | 900* |
| OU1: Output function => | Fno | Fno | Fno |
| dS1: delay switch ON => | 2 sec | 2 sec | 2 sec |
| dr1: delay switch OFF => | 1 sec | 1 sec | 1 sec |
| P-n: Output polarity | PnP | PnP | PnP |
| dAP: damping => | 500 msec | 500 msec | 500 msec |
| diS: Display update | rd2 | rd2 | rd2 |
| Uni: Display Unit | mbar** | mbar** | mbar** |
| *Not used but should be set anyway. If it is not set there is a risk of the switch making false flashing lights. |
| **Presentation on display is mbar. |
Valid for pressure transmitter 90609-4434 introduced from machine 63202/20133| Pressure Switch Parameter | Valid for: Hygiene level XH | Valid for: Hygiene level AD |
| Pre-treatment | Package Disinfection |
| ou1: Output function => | Fno | Fno | Fno |
| ou2: Output function => | Fno | Fno | Fno |
| FH1: Upper limit value => | 800 mbar | 130 mbar | 800 mbar |
| FL1: Lower limit value => | 200 mbar | 60 mbar | 200 mbar |
| FH2 | 1000* | 1000* | 1000* |
| FL2 | 990* | 990* | 990* |
| dS1: delay switch ON => | 2 sec | 2 sec | 2 sec |
| dr1: delay switch OFF => | 1 sec | 1 sec | 1 sec |
| P-n: Output polarity | PnP | PnP | PnP |
| dAP: damping => | 0.500 sec | 0.500 sec | 0.500 sec |
| diS: Display update | rd2 | rd2 | rd2 |
| uni: Display Unit | mbAr** | mbAr** | mbAr** |
| coLr: Display color | G1ou | G1ou | G1ou |
| *Not used but should be set anyway. If it is not set there is a risk of the switch making false flashing lights. |
| **Presentation on display is mbar. |

- Pressure switch
- Pressure switch
- Display up to machine 63202/20132
- Display from machine 63202/20133
Peroxide Unit - Set Peroxide Pump Spring Tension
| Equipment Status | Program Step |
| Special Equipment | Vessel |
Hazardous substance.When handling peroxide, use protective safety equipment: safety glasses, protective gloves, and an apron.The tubing contain a substance that is hazardous to your health.
- Loosen the peroxide tubing Coupling. Place the free tubing end in a vessel to gather the fluid.

- Coupling
- Remove the Cover.
Moving machinery.When setting the spring tension, be careful.The setting procedure demands that the pump in operation, which means that the rotor is rotating.
Start the Pump at the TPOP, see Procedure - Let the pump run until no air bubbles are seen in the system.

- Cover
- Pump
- Release the spring tension by turning the Setting screw counter clockwise until the Flow meter shows no peroxide flow.
- Increase the spring tension by turning the Setting screw clockwise. Tighten the setting screw two more turns when a peroxide flow is noticeable in the Flow meter.
Valid for: Hygiene level AD
- Setting screw
- Flow meter
- Adjust the stretching of the tubing, see Procedure Peroxide Unit - Adjust Peroxide Pump Tubing.
- Set the correct flow according to:
- Assemble the peroxide tubing coupling and dispose the fluid in the vessel according to local regulations.
- Assemble the pump in the reverse order.
Peroxide Unit - Adjust Peroxide Pump Tubing
| Equipment Status | Program Step |
- Make sure that the Tubing between the Rotor and the Tube holder on the pressure side is stretched.
- If necessary, detach the Tube holder and pull the Tubing carefully.

Left: The tubing is correctly stretchedRight: The tubing is too slack
- Tubing
- Rotor
- Tube holder
Peroxide Unit - Basic Setting of the Peroxide Pump Flow
| Equipment Status | Program Step HEATING |
| Special Equipment | Measuring cylinder TP no. 90459-6810 |
Hazardous substance.When handling peroxide, use protective safety equipment: safety glasses, protective gloves, and an apron.The tubing contain a substance that is hazardous to your health.
- Make sure that the peroxide Tank is filled up.
- Make sure that the spring loaded tension arm on the pump is set according to Peroxide Unit - Set Peroxide Pump Spring Tension.
- Step the machine up to heating.
- Disconnect at the Coupling. Place the free tubing end in a vessel to gather the fluid.
Not valid for: MSK H2O2 Tank Level Probe TT/3 3752157-0100
- Tank
- Coupling
Valid for: MSK H2O2 Tank Level Probe TT/3 3752157-0100
- Tank
- Coupling
- Start the Pump at the TPOP according to procedure Peroxide Unit - Setting on TPOP Item Peroxide Unit - Setting on TPOP to Peroxide Unit - Setting on TPOP. Let the pump run until no air bubbles are seen in the system.
- Gather fluid in the measuring cylinder according to the time specified in the table below.
| Peroxide flow | Time | Volume |
| Valid for: Hygiene level AD | 0.15 l/h | 4 min | 10 ml |
| = 150 ml/h = 10 ml/4 min |
- Stop the peroxide pump at the TPOP, see Procedure Peroxide Unit - Setting on TPOP.
- Measure and check that the gathered peroxide fluid volume is according to the table above. If necessary, adjust the pump rotation speed on the TPOP.
- When the correct value are set, make a mark on the Flow meter.
- Connect the hose back to the heater.
- Adjust the flow indication level on the Flow meter until it reaches the mark.
- Step the machine down to step zero.
- Dispose the fluid in the vessel and the measuring cylinder according to local regulations.

- Pump
- Flow meter
Peroxide Unit - Basic Setting of the Peroxide Pump Flow
| Equipment Status | Program Step heating |
| Special Equipment | Measuring cylinder TP no. 90459-6810 |
Hazardous substance.When handling peroxide, use protective safety equipment: safety glasses, protective gloves, and an apron.The tubing contain a substance that is hazardous to your health.
- Make sure that the peroxide Tank is filled up.
- Make sure that the spring loaded tension arm on the pump is set according to Peroxide Unit - Set Peroxide Pump Spring Tension.
- Step the machine up to heating.
- Disconnect at the Coupling. Place the free tubing end in a vessel to gather the fluid.
Not valid for: MSK H2O2 Tank Level Probe TT/3 3752157-0100
- Tank
- Coupling
Valid for: MSK H2O2 Tank Level Probe TT/3 3752157-0100
- Tank
- Coupling
- Start the Pump at the TPOP according to procedure Peroxide Unit - Setting on TPOP Item Peroxide Unit - Setting on TPOP to Peroxide Unit - Setting on TPOP. Let the pump run until no air bubbles are seen in the system.
- Gather fluid in the measuring cylinder according to the time specified in the table below.
| Peroxide flow | Time | Volume |
| Valid for: Hygiene level XHPackage Disinfection | 0.3 l/h | 2 min | 10 ml |
| = 300 ml/h = 10 ml/2 min |
| Valid for: Hygiene level ADPackage Disinfection | 0.6 l/h | 1 min | 10 ml |
| = 600 ml/h = 10 ml/1 min |
- Stop the peroxide pump at the TPOP, see Procedure Peroxide Unit - Setting on TPOP.
- Measure and check that the gathered peroxide fluid volume is according to the table above. If necessary, adjust the pump rotation speed on the TPOP.Note: When the correct value are set, read the peroxide flows on the Flow meter, and make notes. This can come in handy when setting the flow without making new flow measurements.

- Pump
- Flow meter
- Step the machine down to step zero.
- Assemble the peroxide tubing coupling and dispose the fluid in the vessel and the measuring cylinder according to local regulations.
Peroxide Unit - Set Pressure Switch Peroxide
| Equipment Status | Program Step heating |
- Make sure that following condition is fulfilled.
| Valid for: Hygiene level XH | Valid for: Hygiene level AD |
| Pre-treatment | Package Disinfection |
| Air flow | 1600 l/h | 800 l/h | 1600 l/h |
- Step the machine up to heating.When the correct temperature is reached force the peroxide system at the TPOP, see Procedure:Peroxide Unit - Setting on TPOPorPeroxide Unit - Setting on TPOP
- Run for at least five minutes to stabilise the peroxide system.
- Set peroxide flow, see procedure Peroxide Unit - Basic Setting of the Peroxide Pump Flow on page Peroxide Unit - Basic Setting of the Peroxide Pump Flow. Read the actual value on the display of the Pressure switch, H2O2 and the Pressure switch, H2O2, and make a note.
- Valid for: Valid for pressure transmitter 90459-1994 up to machine 63202/20132Set the upper limit value and the lower limit value for the Pressure switch, H2O2 and the Pressure switch, H2O2.
| Pressure Switch Parameter | |
| SP1: Upper limit value => | Read value (see Item Reference) +100 mbar * |
| rP1: Lower limit value => | Read value (see Item Reference) -100 mbar * |
| OU1: Output function => | Fno |
| dS1: delay switch ON => | 2 sec |
| dr1: delay switch OFF => | 1 sec |
| P-n: Output polarity | PnP |
| dAP: damping => | 500 msec |
| diS: Display update | rd2 |
| Uni: Display Unit | mbar** |
| * example: If the read value = 250 mbar then upper limit value = 350 mbar and lower limit value = 150 mbar |
| **Presentation on display is mbar. |
- Valid for: Valid for pressure transmitter 90609-4434 introduced from machine 63202/20133Set the upper limit value and the lower limit value for the Pressure switch, H2O2 and the Pressure switch, H2O2.
| Pressure Switch Parameter | |
| ou1: Output function => | Fno |
| ou2: Output function => | Fno |
| FH1: Upper limit value => | Read value (see Item Reference) +100 mbar * |
| FL1: Lower limit value => | Read value (see Item Reference) -100mbar * |
| dS1: delay switch ON => | 2 sec |
| dr1: delay switch OFF => | 1 sec |
| P-n: Output polarity | PnP |
| dAP: damping => | 0.500 sec |
| diS: Display update | rd2 |
| uni: Display Unit | mbAr** |
| coLr: Display color | G1ou |
| * example: If the read value = 250 mbar then upper limit value = 350 mbar and lower limit value = 150 mbar |
| **Presentation on display is mbar. |
- Step the machine down to STEP ZERO

- Display up to machine 63202/20132
- 2O2Pressure switch, H
- 2O2Pressure switch, H
- Display from machine 63202/20133
Peroxide Unit - Setting on TPOP
| Equipment Status | Program Step air on |
- Press Manoeuvre window.
- Press Carton section to enter the
Setting and Information Carton Section window. - Step the machine up to heating.
- Press Service key.

- Manoeuvre window
- Carton section
- Service key
- Press Peroxide nozzle to view the peroxide pump settings.
Risk of equipment damage.Do not start the peroxide pump until the evaporator has reached its working temperature.
Press On to start the peroxide pump.- Press Enable increase/decrease to enable the
Peroxide pump setting menu. Press Increase or Decrease to adjust the peroxide pump speed. - Press Exit to leave the
Peroxide pump setting menu. 
- Peroxide nozzle
- On
- Enable increase/decrease
- Increase
- Decrease
- Exit
Peroxide Unit - Setting on TPOP
| Equipment Status | Program Step |
- Press Manoeuvre window.
- PressPackage disinfection to enter the
Setting and Information Package Disinfection window. 
- Manoeuvre window
- Package disinfection
- Press Package disinfection and pressOn to enable the package disinfection function.
- Step the machine up to heating.
- Press Service key.

- Package disinfection
- On
- Service key
- Press Peroxide nozzle to view the peroxide pump settings.
Risk of equipment damage.Do not start the peroxide pump until the evaporator has reached its working temperature.
PressOn to start the peroxide pump.- PressEnable increase/decrease to enable the peroxide pump setting menu. Press Increase orDecrease to adjust the peroxide pump speed.
- Press Exit to enter
Manoeuvre Window. 
- Peroxide nozzle
- On
- Enable increase/decrease
- Increase
- Decrease
- Exit
Peroxide Unit - Clean Peroxide Filter
| Equipment Status | Program Step step zero |
Chemical Hazard.The connections contain a substance that is hazardous to your health.
- Remove the two Screw and washer and turn the Panel to get access to the back.

Left: Panel for Pre-treatmentRight: Panel for Package Disinfection
- Screw and washer
- Panel
- For all Peroxide filter do the substeps below:
- Assemble the panel in the reverse order.

Left: Panel for Pre-treatmentRight: Panel for Package Disinfection
- Peroxide filter
- Hose
- Filter holder
- Filter holder
- Filter
- Gasket
- Step the machine up to heating.
- Force the peroxide pumps at the TPOP. Run them until all the air is evacuated.
- Stop the peroxide pumps at the TPOP.
- Step the machine down to step zero.
Peroxide Unit - Clean Nozzle
| Equipment Status | Program Step step zero |
| Consumables | Sealing compound: TP No. 90605-6744 (Alternative 2) |
Risk of burns.Wait for it to cool down before starting any work on it.The heater can be hot.
When the nozzle is clogged, try Alternative 1 first before the more extensive Alternative 2 (on the next page).Alternative 1
- Clean the nozzle by pressing the Button, which effects the Needle and clears the Fluid nozzle.

- Button
- Needle
- Fluid nozzle
Alternative 2
- Remove the evaporator from the machine according to Procedure:
- Separate the Nozzle and the Heater by turning the nozzle.Note: When dismantling, be careful not to loose the Air cap or the Gasket and the Gasket.
- Disconnect the Fluid nozzle from the Adapter.
- Disconnect the Fluid nozzle from the Spray body. Be careful with the Gasket.
- Disconnect the Needle from the Spray body.
- Carefully remove old sealing rests from the Fluid nozzle. Clean the Fluid nozzle with compressed air.
- Assemble the Nozzle in the reverse order.Note: If the Adapter has been removed from the Heater use sealing compound between the adaptor and the heater. Apply the sealing compound very moderate otherwise there is a risk that the sealing compound plugs the nozzle.
- Step the machine up to heating and force at the TPOP the peroxide system. Run for about 5 minutes to ensure that the system is bleeded.

- Nozzle
- Heater
- Air cap
- Gasket
- Gasket
- Fluid nozzle
- Adapter
- Spray body
- Needle
Peroxide Unit - Remove Evaporator
| Equipment Status | Power must be turn OFF.
|
Burn hazard.Allow the heater to cool down before starting any work on it.The heater can be hot.
Loosen the Screw and remove the Protection cover.Hazardous substance.When handling peroxide, use protective safety equipment: safety glasses, protective gloves, and an apron.The
Peroxide hose contain a substance that is hazardous to your health.
Disconnect the Air hose and the Peroxide hose.
- Screw
- Protection cover
- Air hose
- Peroxide hose
Hazardous voltage.The main power supply disconnector must be switched off and secured with a lock before starting any work on the electrical equipment.Will shock, burn or cause death.
Remove the Cover and disconnect the Wire at the Terminal block in the Connection box.- Disconnect the Thermocouple.
- Disconnect the Coupling.
- Remove the Screw and washer and the Holder to bring the evaporator down.

- Cover
- Wire
- Terminal block
- Connection box
- Thermocouple
- Coupling
- Screw and washer
- Holder
Peroxide Unit - Remove Evaporator
| Equipment Status | Power must be turn OFF.
|
Burn hazard.Allow the heater to cool down before starting any work on it.The heater can be hot.
Remove the Screw. Remove the Protection cover.Hazardous substances.When handling peroxide, use protective safety equipment: safety glasses, protective gloves, and an apron.The
Peroxide hose contain a substance that is hazardous to your health.
Disconnect the Air hose and the peroxide hose (4).
- Screw
- Protection cover
- Air hose
- Peroxide hose
Hazardous voltage.The main power supply disconnector must be switched off and secured with a lock before starting any work on the electrical equipment.Will shock, burn or cause death.
Remove the Cover and disconnect the Wire (6) at the Terminal block in the Connection box.- Disconnect the Thermocouple.
- Disconnect the Coupling.
- Remove the Screw and the Holder to bring the evaporator down.

- Cover
- Wire
- Terminal block
- Connection box
- Thermocouple
- Coupling
- Screw
- Holder
Peroxide Unit - Change Air Filter
| Equipment Status | Program Step step zero |
- Remove the two Screw and washer and turn the Panel to get access to the back.

Panel for Pre-treatment

Panel for Package Disinfection
- Screw and washer
- Panel
- Disconnect the Hose to the Air filter.
- Pull the Air filter gently out of the Clip.
- Change the Air filter , remove the Coupling and the Coupling and attach them on the new filter. Leave 8.5 ±0.5 mm of the thread visible when tightening the couplings.Note: Do not tighten the couplings too much, as they may break.
- Assemble the panel in the reverse order.

Panel for Pre-treatmentPanel for Package Disinfection
- Hose
- Air filter
- Clip
- Coupling
- Coupling
Peroxide Unit - Change Heater
| Equipment Status | Power must be turn OFF.
|
| Special Equipment | Steel wool |
Burn hazard.Allow the heater to cool down before starting any work on it.The heater can be hot.
- Remove the evaporator from the machine according to procedure
- Disconnect the wire from the Heater at the Terminal block in the Connection box.
- Remove the Connection box.
- Separate the Heater from the Evaporator.
- Check that the Insulating material is intact.
- Change the Heater.

- Heater
- Terminal block
- Connection box
- Evaporator
- Insulating material
- Check inside the evaporator for sediment. If necessary, remove the sediment using a steel wool.
- Assemble in the reverse order. See also the procedures:
- Turn the TT/3 main power supply disconnector on.
- Step the machine up to heating and force at the TPOP the peroxide system, run for about five minutes to ensure that the system is bleeded.
Peroxide Unit - Change Peroxide Pump Tubing
| Equipment Status | Program Step |
Hazardous substance.When handling peroxide, use protective safety equipment: safety glasses, protective gloves, and an apron.The hose (3) contain peroxide that is hazardous to your health.
- Remove the Cover.
- Detach the spring loaded Tension arm by lifting the Spring bar.
- Disconnect the Tubing from the pressure side at the Barbed connector and from the suction side at the Barbed connector.
- Detach the tubing from the Tube holder.

- Cover
- Tension arm
- Spring bar
- Tubing
- Barbed connector
- Tube holder
- Install the new tubing according to the table below.Note: In machine variants AD, ADY, ASD, ASCM, and AW there are two different kinds of pump tubing. The difference between the inner diameter of the tubing used for the pre-treatment system and the tubing for the package disinfection system are barely noticeable. The tubing for package disinfection pumps in machine variants AD, ADY, ASD, ASCM, and AW must be the ones with the small flags attached on the surface.
| Valid for: Hygiene level XH | Valid for: Hygiene level AD |
| | Pre-treatment | Package Disinfection |
| TP no. | 90459-4643 | 90459-4643 | 90600-3485 |
| Inner diameter | A = 2.4 mm | A = 2.4 mm | B = 3.2 mm |
| Length Side 1 | 800 mm | 800 mm | 800 mm |
| Length Side 2 | 600 mm | 600 mm | 600 mm |
|  |
- Adjust the stretching of the tubing. See Procedure Peroxide Unit - Adjust Peroxide Pump Tubing.
- Set the spring tension. See Procedure Peroxide Unit - Set Peroxide Pump Spring Tension.
- Assemble the pump in the reverse order.
Peroxide Unit - General Instructions Pressure Switch
| Equipment Status | Program Step heating |
Refer to the instructions and procedures below when setting the pressure switch.- Controls and Indicating Elements, see page Controls and Indicating Elements
- Menu Structure, see page Menu Structure
- Programming, see page Programming
- Turning the Display, see page Turning the Display
Controls and Indicating Elements
| Pos | Denomination | Description |
| 1 | LED green | Lighting LED = display unit (mbar) |
| 2 | 2 x LED yellow | Switching status; lights if the respective output has switched. |
| 3 | 4-digit alphanumerical display | Display of the system pressure (mbar). Display of parameters and parameter values. |
| 4 | Set button | Setting of the parameter values (scrolling by holding pressed; initialized by pressing briefly). |
| 5 | Mode/ Enter button | Selection of the parameters and acknowledgement of the parameter values. |

- RUN
- Normally not used
- Not used
Programming

A: Select ParametersB: Set ValuesC: Confirm Values
Turning the Display
To turn the Alphanumerical display 180° set the parameter, display update (diS), according to the table below.| Pressure Switch Parameter |
| diS: Display update | rd2 |

- Alphanumerical display
Peroxide Unit - General Instructions Pressure Switch (Valid from machine 63202/20133)
| Equipment Status | Program Step HEATING |
Refer to the instructions and procedures below when setting the pressure switch.- Controls and Indicating Elements, see page Controls and Indicating Elements.
- Menu Structure, see page Menu Structure.
- Programming, see page Programming.
- Turning the Display, see page Turning the Display.
Controls and Indicating Elements
| Pos | Denomination | Description |
| 1 | Indicator LEDs | Switching status OUT1 (lights when output 1 is switched). |
| 8 | Indicator LEDs | Switching status OUT2 (lights when output 2 is switched). |
| 2-7 | Indicator LEDs | System pressure in the indicated unit of measurement. |
| 9 | Enter button | Selection of the parameters and acknowledgement of the parameter values. |
| 10-11 | Arrow keys up and down | Setting of the parameter values (scrolling by holding pressed; incremental by pressing |
| 12 | Alphanumeric display, 4 digits | Display of the current system pressure.Indication of the parameters and parameter values. |

- RUN
Programming

A: Select ParametersB: Set ValuesC: Confirm Values
Change from menu level 1 to menu level 2Turning the Display
To turn the Alphanumerical display 180° set the parameter, display update (diS), according to the table below.| Pressure Switch Parameter |
| diS: Display update | rd2 |

- Alphanumerical display
Functional Description
A Servomotor drives the cam module for cutting and folding, and the curve unit. The motor is equipped with a brake to prevent unintentional movement by hand. The brake also prevents movement if energy is built up in the system when the servomotor power is cut after the doors are opened, for instance spring force from the pusher or from mechanical parts after a crash.The machine can not be cranked by hand. All movements must be made by the control panel.The control of the servomotors is synchronised with the rest of the machine by the PLC system.The servomotor drives a Planetary gear (PV10) 4:1, which drives a Worm gear (SV5) 7.25:1. The reason for the two gear solution is that if all of the gear ratio were done by the worm gear, it would become self-locking. If there is too prompt a stop of the servomotor, the self-locking could damage the worm gear. Another reason is that a higher gear change results in a lower efficiency with more heat released as a consequence.
- Servomotor
- Planetary gear (PV10)
- Worm gear (SV5)
In the rear section of the machine, the Worm gear (SV5) drives a Bevel gear (VV9) with gear ratio 1:1. On the two Output shaft, there is one cam for cutting functions and one for folding functions.Ahead in the machine the worm gear drives a Bevel gear (VV7) with gear ratio 1:1. It has only one Output shaft which drives the curve unit, also called record player or jukebox. Between the worm gear and the Bevel gear (VV7) there is an Overload clutch that releases at 400 Nm. The normal torque is 220-250 Nm during PRODUCTION. The overload clutch can only be engaged in one position and with that the synchronization is maintained. A proximity switch senses when the clutch has released and stops the machine.The Worm gear (SV5), and the Bevel gear (VV7) and the Bevel gear (VV9) have sensors for the oil levels. During operation so is the oil not checked because of the risk for false alarms due to that the oil is tossed around in the gears.The oil level is checked one minute after every operation, if the oil level is low a blue alarm will occur. The blue alarm turns to a yellow alarm after one more hour of operation and then it is not possible to continue operation without filling oil.The Planetary gear (PV10) is filled with grease.
- Servomotor
- Planetary gear (PV10)
- Worm gear (SV5)
- Output shaft
- Bevel gear (VV7)
- Overload clutch
- Output shaft
- Bevel gear (VV9)
Cam Module (Cut and Fold)
Drive Unit - Check Cam Module (Cut and Fold)
| Equipment Status | Program Step |
- Check that the Cylinder do not leak.
- Check that there are no play in the Cylinder bracket, the Link head , and the Bushing.
- Change if required.

- Cylinder bracket
- Cylinder
- Link head
- Bushing
Drive Unit - Set Cam Module (Cut and Fold)
| Equipment Status | Program Step step zero |
| Special Equipment | Zeroing rod TP No. 977709-0000 |
| Consumables | Food Grade Hydraulic Oil: TP No. 1607001-0000 (valid from machine 63202/20067 or for machines with UK-3355833-0100) Hydraulic Oil: TP No. 344474-4603 (valid for machines up to 63202/20066, without UK-3355833-0100) |
Set Cams (Cut and Folder)
- If the Clamp element has been removed, lubricate the screws and the Conical surfaces (gray marked area) lightly with hydraulic oil.
- The shaft and the Not conical surface are to be cleaned with white spirit or similar, and let to dry before fitting.Note: Do not use grease or oil with added molybdenum sulphide or high-pressure agents.
- Slide the cams on the hub, followed by the Clamp element. The slots in the cones are to be turned 180° related to each other.
- Insert the Zeroing rod through the cams and the holder.

- Zeroing rod
- Zero setting hole
- Clamp element
- Screw
- Not conical surface
- Conical surfaces
- Tighten the Screw crosswise by hand and align the Clamp element at the same time. Tighten the Screw crosswise in several steps by a torque wrench; start at 5 Nm, and continue in 5 Nm steps, until the full torque 28 Nm is obtained.
- Continue tightening the Screw to the right with 28 Nm, several revolutions, until the Clamp element has reached its bottom position.
- Remove the Zeroing rod.
- If the coupling to the SV5 has been removed, see Procedure Drive Unit - Assemble Shafts and Couplings on page Drive Unit - Assemble Shafts and Couplings.

- Zeroing rod
- Zero setting hole
- Clamp element
- Screw
- Not conical surface
- Conical surfaces
Drive Unit - Set Overload Clutch
| Equipment Status | Program Step |
Set the overload clutch to 400 Nm by loosening the three socket head cap screws on the Ring. Turn the Ring with an adjustable spanner.Note: By turning the overload clutch to the right it will disengage at a lower torque.
- Ring
Drive Unit - Change Cam Rollers (Cut and Fold)
| Equipment Status | Program Step |
Cam Roller - Folder
- Turn off the supply of air so that the Cylinder is without pressure.
- Lift the Arm by hand so that the Cam roller is raised off the cam.
- Remove the Nut and change the cam roller.
- Assemble in the reverse order.
Cam Roller - Cutting
- Remove the Screw and unhook the Spring from its upper attachment point.
- Lift the Arm by hand so that Cam roller is raised off the cam.
- Remove the Nut and change the cam roller.
- Assemble in the reverse order.
- Set the cams, see Procedure Drive Unit - Set Cam Module (Cut and Fold) on page Drive Unit - Set Cam Module (Cut and Fold).

- Cylinder
- Arm
- Arm
- Screw
- Cam roller
- Spring
- Nut
- Nut
- Cam roller
Drive Unit - Homing
| Equipment Status | Program Step |
| Special Equipment | Zeroing rod TP No. 977709-0000 Zeroing rod TP No. 988851-0000 |
- Connect a keyboard to the TPOP.
- Press the F4 button on the keyboard to open the Technical Menu.
- Press Servo to open the Servo Technical window.

- Servo
- Press Reset to reset the home position.
- Exit the Servo Technical window and the Technical Menu.
- Step the machine up to Air on. This causes a Servomotor Position alarm.
- Reset the alarms.

- Reset
- Inch the Servomotor to MSP 0 on the Protractor, according to the illustration.Note: Use the zeroing rod to confirm MSP 0. Make sure that the zeroing rod has been removed before you continue.
- Press the F4 button on the keyboard to open the Technical Menu.
- Press Servo to open the Servo Technical window.
- Press Calibrate to do the calibration.
- Exit the Servo Technical window and the Technical Menu. The alarm regarding the servomotor position disappears
- Press
Save.
Oil Filling (VV9, SV5, VV7 and PV10)
Note: Do not mix synthetic and mineral oils.Note: For Oil Specifications. See Chapter .| Gear box | Oil type | Quantity (l) | Remark |
| VV9 | 344410-0000*90458-2734** | 2.8 | VV9 is accessible through ASU. Draining: Removing drain plug, use a suction pump for remaining oil.Filling: Start with alarm for low level, fill up until alarm goes out, thereafter further filling with 0.2 L. |
| SV5 | | | No oil change, lubricated for lifetime. |
| VV7 | 344410-0000*90458-2734** | 1.3 | VV7 is easy accessible if LFU S2 is removed.Draining: Remove drain plug, use a suction pump for remaining oil.Filling: Start with alarm for low level, fill up until alarm goes out, thereafter further filling with 0.2 L. |
| PV10 | | | No oil change, lubricated for lifetime. |
| *Valid from machine 63202/20067 or for machines with UK-3355833-0100.**Valid for machines up to 63202/20066, without UK-3355833-0100. |

- Drain plug
- Level guard
- Filling plug/nipple
Drive Unit - Assemble Shafts and Couplings
| Equipment Status | Program Step |
| Special Equipment | Zeroing rod TP No. 977709-0000 Zeroing rod TP No. 988851-0000 |
| Consumables | Flange Sealant Loctite 574, TP No. 344453-0050 |
| Shaft | Connected to gearbox | Clamping hub Torque (Nm) |
| A | VV9 - SV5 | 200 |
| B | Servomotor - PV10 | 81 |
| C | PV10 - SV5 | 50 |
| D | VV7 - SV5 | 250 |
General
When work is to be done on drive unit in carton section, a good advice is to secure with the zero setting rods before the system is disassembled. Otherwise there is a risk that settings are disturbed and a new calibration has to be done.Coupling Between VV9 and SV5 - Assemble
- Insert the Zeroing rod (977709) in the Zero setting hole for the Cam module cut and fold.
- To get the correct synchronisation position against the SV5, insert the zeroing rod into the Cam module erector, see Couplings Between VV7 and SV5 - Assemble.Note: Make sure that there is no grease on the shafts for VV9, SV5 and on contact surfaces for the Coupling.
- Distribute the Coupling so it has equal connection into both shafts, VV9 respectively SV5, tighten the screws with 250 Nm.
- If necessary calibrate the Servomotor, see Procedure Drive Unit - Homing on page Drive Unit - Homing.

- Cam module erector
- Cam module cut and fold
- Zero setting hole
- Coupling
- Zeroing rod (977709)
- Servomotor
Couplings Between VV7 and SV5 - Assemble
- Synchronize the Curve unit by inserting the Zeroing rod (988851) into the Cam shaft.
- To get the correct synchronisation position against the SV5, insert the zeroing rod into the Can module cut and fold, see Coupling Between VV9 and SV5 - Assemble on page Coupling Between VV9 and SV5 - Assemble.Note: Make sure that there is no grease on the shafts for the SV5, VV7 and on contact surfaces for the Coupling.
- Distribute the Shaft so that the Coupling has equal connection into SV5 and VV7 shafts. Tighten the Coupling screws with 250 Nm.
- Set the distance A between the Proximity switch and the flange.
- If necessary calibrate the Servomotor, see Procedure Drive Unit - Homing on page Drive Unit - Homing.

A (mm) = 0.2-0.5
- Proximity switch
- Curve unit
- Servomotor
- Shaft
- Coupling
- Can module cut and fold
- Zeroing rod (988851)
- Cam shaft
Coupling Between PV10 and SV5 - Assemble
- Fit the Coupling on PV10, align the Coupling clamping device flush with the PV10 axle end, see the following illustration.
- Tighten the Coupling screw with 50 Nm.
- Assemble the Coupling on the SV5, tighten the Coupling clamping device slightly so that the Coupling can slide in axial direction.Note: Fit the Coupling so high that it is pushed downwards when the PV10 is assembled. In the same time, check so that the Coupling is reachable through the Hole.Note: Align also the Coupling clamping device so that it is reachable through the holes in the SV5.
- Apply Flange Sealant on both PV10 and SV5 flange.
- Assemble the PV10, put the feeler gauges (1.0 mm) between the PV10 flange and the SV5 flange. Align the Hole toward ASU.
- Tighten the Coupling with 50 Nm.
- Remove the feeler gauges, assemble and tighten the Screw.Note: The Coupling and the Coupling will now preload correctly.
- Assemble the servomotor, see Procedure Servomotor - Change on page Servomotor - Change.

- PV10 axle end
- PV10
- Coupling
- Coupling
- SV5
- Coupling
- Hole
- Screw
Overview
| Pos. | Denomination | Cross reference |
| 1 | Link arms (Side Feeder, Distributor & Erector) | See Curve Unit |
| 2 | Link arm (Pusher & Stripper) | See Link Arms |
| 3 | Cam Shaft | See Cam Shaft |
Curve Unit - Set Link Arms
| Equipment Status | Program Step |
Link Arm (side feeder), Link Arm (distributor) and Link Arm (erector)
Carry out basic setting, according to the table below.| Distances | A (mm) | B (mm) | C (mm) |
| Base | 545.0 ±0.5 | 574.0 ±0.5 | 233.0 ±0.5 |
| Midi | 545.0 ±0.5 | 574.0 ±0.5 | 233.0 ±0.5 |
| Mini | 545.0 ±0.5 | 575.0 ±0.5 | 233.0 ±0.5 |
| Micro | 545.0 ±0.5 | 575.0 ±0.5 | 233.0 ±0.5 |
| Format S1/S2 | D (mm) | E (mm) |
| Base/Base | 25 ±1 | 111 ±1 |
| Base/Midi | 31.5 ±1 | 117 ±1 |
| Base/Mini | 19 ±1 | 116 ±1 |
| Base/Micro | Not yet available | Not yet available |
| Midi/Midi | 32 ±1 | 122 ±1 |
| Midi/Mini | 25 ±1 | 124 ±1 |
| Midi/Micro | 20 ±1 | 128 ±1 |
| Mini/Mini | 28.5 ±1 | 129 ±1 |
| Mini/Micro | 26 ±1 | 133 ±1 |
| Micro/Micro | 27 ±1 | 135 ±1 |
Note: If measure D or E is missing, set link arms when setting erector carriages.
- Link arm (side feeder)
- Link arm (distributor)
- Link arm (erector)
Setting of Cam Rollers (for Side Feeder, Distributor, Erector, Pusher and Stripper)
- Check the distance A, as illustrated, for the five cam rollers.
- If required, loosen the Screw and raise or lower the link arm until the cam roller distance is correct.
- Tighten the Screw.

A (mm) = 0.8 ±0.2
- Cam
- Cam roller
- Link arm
- Screw
Curve Unit - Remove Cam Unit
| Equipment Status | Program Step |
| Special Equipment | Zeroing rod TP No. 988851-0000 |
- Inch the machine to MSP 938.
- Step the machine down to step zero.
- Let the machine cool down before continuing on item d).
Hazardous voltage. The main power supply disconnector must be switched off and secured with a lock before starting any work on the electrical equipment. Will shock, burn, or cause death.
Remove the Heater (LS-oven) by removing the cooling hoses, electrical cables, and air hoses.- Remove the Screw.

- Heater
- Screw
- Remove the Slide rail by removing the Hand knob.
- Remove the pusher frame by removing the Screw and push back the pusher rods.
- Remove the Screw, the Screw, and the Screw.
- Mark the position of the stripper link bracket and remove the Screw.

- Slide rail
- Hand knob
- Screw
- Screw
- Screw
- Screw
- Screw
- Mark the position of the side feeder frame and remove the side feeder, see Procedure Side Feeder - Remove on page Side Feeder - Remove.
- Remove the conveyor by loosening the fibre optic connections on the sleeve conveyor, disconnect also the cooling hoses and the cable connections.
- Remove the Screw and the Screw and lift out the conveyor.
Heavy equipment.It is recommended to use two persons when removing the conveyor. Handle the conveyor with care and make sure that you take precautions to handle the weight.The conveyor is heavy and can cause personal injuries and damage to equipment.
Loosen the Screw in the coupling to make it possible to turn the cam unit around.
- Loosen the Link arm (Pusher), the Link arm (Stripper), the Link arm (Side Feeder), the Link arm (Distribution Drive), and the Link arm (Erector) from machine side 1.

- Link arm (Pusher)
- Link arm (Stripper)
- Link arm (Side Feeder)
- Link arm (Distribution Drive)
- Link arm (Erector)
- Loosen the Cam roller of the pusher.
- Let down the Stripper arm from machine side 2.
- Measure the distances between the cams that are to be changed.

- Cam roller
- Stripper arm
- Locate, under the cam unit, two pieces of 100 x100 mm wooden beams, according to illustration below. Remove the Bearing and the Bearing. Push and lift out the cam unit with an iron bar and a piece of wood, between the gear box and the cam shaft.
Heavy equipment.It is recommended to use two persons when removing the cam unit. Handle the cam unit with care and make sure that you take precautions to handle the weight.The cam unit is heavy and can cause personal injuries and damage to equipment.
Remove the upper cam unit (cams for distributor and erector).- The lower part of the cam unit is now possible to lift down, for handling on a pallet. Be aware of the 0-holes in the cams.

- Bearing
- Bearing
- Overhaul of the cams, setting of the cams with the Zero-setting tool, and tightening of the clamp element in the cam unit, is to be done in accordance with following pages.
Overhaul: see Procedure Cam Shaft - Overhaul on page Cam Shaft - Overhaul.Change cams: see Procedure Cam Shaft - Change Cams on page Cam Shaft - Change Cams.Set cams: see Procedure Cam Shaft (Erector) - Set Cams on page Cam Shaft (Erector) - Set Cams.
A (mm) =125 ± 0.5
B (mm) = 280 ± 0.5
- Zero-setting tool
Curve Unit - Overhaul Link Arms
| Equipment Status | Program Step |
Link Arm: Side Feeder, Distributor and Erector - Change Bearings
- Remove the Nut and the Rod .
- Loosen the hoses for the lubrication.
- Remove the eight Screw at the four Clamp .
- Remove the shafts and the link arms.
- Change all the six bearings.
- Assemble in the reverse order.

A: Link arm (side feeder)B: Link arm (distributor)C: Link arm (erector)
- Clamp
- Screw
- Nut
- Rod
Link Arm (pusher and stripper) - Change Bearings
- Disconnect the Link arm Stripper and the Link arm Pusher.
- Remove the Lubrication hose.
- Remove the Screw, the Washer and the Clamp.
- Remove the shaft and the link arms.
- Change the Bearing and the Bearing.
- Assemble in the reverse order.

- Screw
- Washer
- Clamp
- Link arm Stripper
- Link arm Pusher
- Lubrication hose
- Bearing
- Bearing
Curve Unit - Assemble Cam Unit
| Equipment Status | Power must be turn OFF.
|
Hazardous voltage.The main power supply disconnector must be switched off and secured with a lock before starting any work on the electrical equipment. Will shock, burn, or cause death.
- Fit the cam shaft, see Procedure Cam Shaft - Fit on page Cam Shaft - Fit.
- Assemble the cam unit in the reverse order according to Procedure Curve Unit - Remove Cam Unit on page Curve Unit - Remove Cam Unit. Tighten the Screw in coupling to 250 Nm.
- Check synchronization according to Couplings Between VV7 and SV5 - Assemble.

- Screw
Curve Unit - Set Slide Part
| Equipment Status | Program Step step zero |
- Loosen the Screw.
- Set the distance A between the Rod and the Plate, underneath the link arm.
- Tighten the Screw.

A = 0.5 ±0.1 mm
- Screw
- Rod
- Plate
Link Arms - Pusher - Basic Set
| Equipment Status | Program Step |
- Loosen the screws and nuts on the link arm.
- Carry out basic setting according to the table below.
| J (mm) | K (mm) | L (mm) |
| Base, Midi, Mini & Micro | 171.0 ±0.5 | 420.0 ±0.5 | 268.0 ±0.5 |
- Tighten the screws and the nuts.

Left: Side 1Right: Side 2
Link Arms - Stripper - Basic Set
| Equipment Status | Program Step |
- Loosen the screws and nuts on the link arm.
- Carry out basic setting according to the table below.
| M (mm) | N (mm) | O (mm) |
| Base | 400.5 ±0.5 | 410.0 ±0.5 | 268.0 ±0.5 |
| Midi | 404.0 ±0.5 | 357.0 ±0.5 | 268.0 ±0.5 |
| Mini | 404.0 ±0.5 | 357.0 ±0.5 | 268.0 ±0.5 |
| Micro | 404.0 ±0.5 | 357.0 ±0.5 | 268.0 ±0.5 |
- Tighten the screws and nuts.

Left: Side 1Right: Side 2
Link Arms - Change Cam Rollers
| Equipment Status | Program Step step zero |
| Consumables | Thread locker: TP No. 351532-0000 |
- Remove the link arm.
- Change the Cam roller.
- Apply thread locker on the threads and tighten the Nut to 120 Nm.

- Nut
- Cam roller
Link Arms - Change Safety Clutch Bearings
| Equipment Status | Program Step |
- Mark the position of the Bracket on the link arm.
- Remove the Screw, the Nut and remove the link arm.
- Remove the four Screw from the bracket and pull the Safety clutch out to get access to the Bearing.
- Remove the Screw and the Screw, dismantle the link arm.
- Press the new Bearing and the Bearing in place with an hydraulic press.
- Put back the Safety clutch.
- The Bracket is to be in marked position when assembling the group. Tighten the screws and the nuts.
- Inch the machine and check, see Procedure Pusher - Set Overtravel on page Pusher - Set Overtravel.

- Bearing
- Bearing
- Screw
- Bracket
- Screw
- Safety clutch
- Nut
- Screw
- Screw
Cam Shaft (Erector) - Set Cams
| Equipment Status | Program Step step zero |
| Special Equipment | Zero-setting tool: TP No. 988851-0000 Torque wrench |
| Consumables | Hydraulic Oil: TP No. 1607001-0000 |
- If the Clamp element and the Clamp element have been removed, lubricate the screws and the Conical surface lightly with hydraulic oil. The Shaft and the Not conical surface are to be cleaned with white spirit or similar, and let to dry before assembling.Note: Do not use grease or oil with added molybdenum sulphide or high-pressure agents.
- Slide on the Hub and the Hub followed by the Clamp element and the Clamp element.

- Clamp element
- Clamp element
- Conical surface
- Shaft
- Not conical surface
- Hub
- Hub
- Insert the Zero-setting tool down through the lower two cams in the lower end section. Tighten the Screw with 40 Nm. Set the distance B between the upper end section and the cam. Tighten the Clamp element according to next item, simultaneously checking the distance.
- Tighten the screws crosswise by hand and align the cams at the same time. Then tighten the screws crosswise in several steps with a torque wrench; start at 5 Nm, and continue in 5 Nm steps, until the full torque 28 Nm is obtained. Continue tightening to the right, to full torque, until no turning movements of the screws. Then finally tighten the screws crosswise twice.
- Insert the Zero-setting tool through the upper two cams and down through lower cams. Tighten the Screw with 40 Nm. Set distance A between the upper end section and the cam. Tighten the Clamp element according to previous item, simultaneously checking the distance.
- Check that the cam rollers run correctly on the cams. See Curve Unit - Set Link Arms on page Curve Unit - Set Link Arms.

A (mm) = 125 ±0.5
B (mm) = 280 ±0.5
- Clamp element
- Clamp element
- Zero-setting tool
- Screw
- Screw
Cam Shaft - Change Cams
| Equipment Status | Program Step |
Remove the shaft and the cams, see Procedure Curve Unit - Remove Cam Unit on page Curve Unit - Remove Cam Unit.Change Cam (A)
- Remove the Screw and change the cam A.
- Tighten the screws finger-tight.
- For zeroing of the cam and tightening of the clamp element, see Procedure Cam Shaft (Erector) - Set Cams on page Cam Shaft (Erector) - Set Cams.
Change Cams (A) and (B)
- Loosen the Screw and remove the Clamp element.
- Remove cam A, the Hub, and the cam B.
- Change the cams, and assemble in the reverse order, tighten the Screw finger-tight.
- For zeroing of the cams and tightening of the clamp element, see Procedure Cam Shaft (Erector) - Set Cams on page Cam Shaft (Erector) - Set Cams.

A: Cam for side feederB: Cam for distributorC: Cam for pusherD: Cam for erector fingers/stripper
- Screw
- Screw
- Clamp element
- Hub
Change Cams (C) and (D)
- Loosen the Screw of the Clamp element.
- Remove the cams C and D, and the Hub downwards.
- Change the cams, and assemble in the reverse order, tighten the Screw finger-tight.
- For zeroing of the cams and tightening of the clamp element, see Procedure Cam Shaft (Erector) - Set Cams on page Cam Shaft (Erector) - Set Cams.
Change all Cams
- First change the two upper cams A and B and utilize zeroing holes in the lower two cams as reference in fitting the upper ones.
- Change the two lower cams C and D, utilizing holes in the upper cams as reference.

A: Cam for side feederB: Cam for distributorC: Cam for pusherD: Cam for erector fingers/stripper
- Screw
- Clamp element
- Hub
Cam Shaft - Fit
| Equipment Status | Program Step |
- Clean the shafts and the inner side of the shaft coupling from oil.
- Assemble the Shaft coupling.
- Put a 24 mm distance lug between the Gear box and the Shaft coupling as a reference.
- Check that the shafts of the gear box and the cam shaft are equally divided in the Shaft coupling.
- Tighten slightly the Screw in the Shaft coupling.
- Remove the distance lug.
- Tighten the Screw, with the tightening torque 250 Nm.

A (mm) = 24 ±1
- Shaft coupling
- Gear box
- Screw
HEPA Unit- Change HEPA-filter
| Equipment Status | Program Step |
| Special Equipment | Detergent Code D Disinfectant Code G1 Soft cloth |
Note: Two service engineers co-operating makes this procedure run smoothly.- Remove the Clamp, the Gasket, and the Hose from the Filter housing.
- Disengage the Locking device and roll out the Filter housing.

The filter housing rolled out in service position
- Clamp
- Gasket
- Hose
- Filter housing
- Locking device
Equipment damage.Always roll out the filter housing on the rails to service position, before removing the screws. Support the filter housing with one hand, while removing the screws as it otherwise will swing downwards.The filter housing can if it is dropped damage the LFU opening tools.
Support the Filter housing with one hand, while removing the Screw.- With the Filter housing hanging vertically, carefully lift it upwards and then forwards to remove it from the Frame.

- Filter housing
- Screw
- Frame
- Place the Filter housing on a clean and suitable working area.
- Remove the four Screw and remove the Lid.
- Remove the four Nut, the Frame, and the HEPA-filter.
- Use a cloth rinsed in a mixture of water and detergent, squeeze it properly and clean manually the inside of the Filter housing and the inside of the Lid.
- Apply disinfectant on the surfaces mentioned above, by using a clean cloth sprayed with disinfectant.
Equipment damage.Be careful when handling and installing the filter as they may easily become deformed. Even small damages will effect the filtration. Install the filter correctly, avoid the guide bars from penetrating the filter.
Put in the new HEPA-filter.Note: Make sure that the gasket of the filter is facing downwards.- Assemble the Frame and tighten the Nut to the mechanical stop.
- Assemble the Lid.

- Filter housing
- Screw
- Lid
- Nut
- Frame
- HEPA-filter
- With the Filter housing vertically, carefully lift and put the Bar in the Holder.
Equipment damage.Always assemble the filter housing in service position, outside the carton section. Support the filter housing with one hand while assembling the screws as it otherwise will swing downwards.The filter housing can if it is dropped damage the LFU opening tools.
With the filter housing horizontally, tighten the Screw.- Roll in the Filter housing.
- Make sure that the rail is secured.

- Filter housing
- Screw
- Bar
- Holder
- Use a cloth rinsed in a mixture of water and detergent, squeeze it properly and manually clean the outside of the Filter housing.
- Apply disinfectant on the surface mentioned above, by using a clean cloth sprayed with disinfectant.
- Assemble the Hose, the Gasket, and the Clamp.
- Step up the machine to heating. Remain in heating for 5 minutes.

- Clamp
- Gasket
- Hose
- Filter housing
Profile - Set
| Equipment Status | Program Step step zero |
| Special Equipment | Template: TP No. 2979587-0000 (MIDI HURON) Template: TP No. 3142127-0000 (MINI SAROMA) |
- Inch the machine so that the mandrels are in horizontal position, positioned toward the cutting unit.
- Move the vertical cylinder to the upper position.
- Fix the Profile in their position, turn them down and lock the Shaft with a hex key.
- Loosen the Screw.

- Profile
- Shaft
- Screw
- Put the Template against the Mandrel.
- Adjust the Profile with the Template.
- Tighten the Screw.
- Check the profiles position with the template, adjust if necessary.Note: This is a default setting of the profiles.

- Profile
- Template
- Mandrel
- Hole
Profile - Set
| Equipment Status | Program Step step zero |
| Special Equipment | Template: TP No. 3446468-0000 (BASE ORINOCO S38 BT) Template: TP No. 3431324-0000 (BASE ORINOCO S38 PB & BASE GOLDECK S38 PB) |
- Inch the machine so that the mandrels are in horizontal position, toward the cutting unit.
- Move the vertical Cylinder to the upper position.
- Turn the Shaft to position the Profile horizontally. Lock the Shaft with a hex key.

- Cylinder
- Shaft
- Profile
- Loosen the Screw.

- Profile
- Screw
- Place the Template against the Inner tool and in the holes in the Profile.
- Adjust the Profile with the Template.
- Tighten the screws while pressing the Template against the Inner tool.
- Check the profiles position with the template. If necessary, loosen the screws and adjust.Note: This is a default setting of the profiles.

- Profile
- Template
- Inner tool
- Remove the hex key and turn up the Shaft.
- Let the vertical Cylinder down.

- Cylinder
- Shaft
Functional Description

A: Sequence 1B: Sequence 2C: Sequence 3D: Sequence 4
- Mandrel
- Profile
- Profile axle
Cutting Unit - Set Vertical Cylinder
| Equipment Status | Program Step step zero |
Note: Make sure the LFU is in the right position before setting the holder.- Fix the Holder for the cutting unit in its upper position.
- Loosen the Screw and the Screw.
- Rotate the Holder until the Holder is parallel (distance A and B must be equal) to the top of the Mandrel.
- Tighten the Screw and the Screw.

- Holder
- Screw
- Screw
- Mandrel
Cutting Unit - Set Profile Axle
| Equipment Status | Program Step step zero |
| Special Equipment | Spirit level |
The distance between the Profile shaft and the top of the Mandrel will be 82 ±1 mm.- Measure the distance A with a steel ruler and calculate the shim thickness B. The shim thickness B = A - 82.Note: If a Shim is necessary, put it between the Bracket for the cutting unit and the Machine body.
- Check so the cutting unit is not touching the cleaning doors.
- Adjust the discharge tray to get a clearance to the cutting unit.Note: On some machines you will not reach the desired value even if you remove all shims.

A = 82 ±1
- Mandrel
- Profile shaft
- Bracket
- Machine body
- Shim
- Check once more the horizontal line for cutting unit with a Spirit level.
- Look along the Mandrel centre line, this line will meet the middle of the Profile shaft or 0 ±1 mm.
- If adjusting is needed see next item.

- Mandrel
- Profile shaft
- Spirit level
- To adjust, loosen the Screw and remove or add the Shim to get the shaft in the correct height against the centreline for the mandrels (see also illustration above).
- Set the profile holder, see Procedure Cutting Unit - Set Vertical Cylinder on page Cutting Unit - Set Vertical Cylinder.

- Screw
- Shim
Cutting Unit - Set Cylinder
| Equipment Status | Program Step step zero |
- Set the distance A between the cylinder house and the Link head.
- Check that the Crank moves inside the grey area, if the Crank moves outside this area it comes in a self-locking position. If necessary, adjust at the Link head.Note: The grey areas exact angle is not possible to give, during the fitting the technician must test where the largest movement can be achieved without reaching the self-locking position.

A (mm) = 10 ±1
- Crank
- Link head
- Check that the Profile are positioned about 90° from the x-axle, when they are in there upper position. Adjust by loosening the Screw and rotate the Profile axle.Note: Fix the Crank to prevent it from rotating.

- Crank
- Profile
- Screw
- Profile axle
- Mandrel
- X-axle
Cutting Unit - Set Stop Block
| Equipment Status | Program Step step zero |
The Stop block must be adjusted so that it bear and guide the Shaft both in the upper position and the lower position.- Loosen the Screw and the Screw.
- Force the vertical cylinder to its upper position.
- Adjust the Clamp block until the stop block just touches the Shaft.
- Tighten the three highest screws to fix the top position.
- Repeat the procedure for the vertical cylinders lowest position.
- Tighten the three lowest screws to fix the lower position.
- Check so the Shaft moves the full stroke easily in the stop block.
- Tighten all the six Screw and the Screw to full torque.Note: The Stop block will guide the shaft and must not restrict the movement of the cylinder. A rapid wear is built in if the stop block is used as a mechanical stop.

- Stop block
- Shaft
- Screw
- Clamp block
- Screw
Cutting Unit - Set Throttle Check Valve
| Equipment Status | Program Step production |
Note: The collecting box must be disassembled during the setting.- Open the Throttle check valve completely by turning the Screw.
- Reduce the air flow until the air flow is too low to blow out the moulding inlets.
- Open the Throttle check valve 1.5 turn.

- Throttle check valve
- Screw
Cutting Unit - Set Guide
| Equipment Status | Program Step tank filling |
- Stop the machine with a pair of Sleeve on the pair of Mandrel approaching the Cassette.
- Inch the machine to move the Sleeve forward until they just reach the top edges of the Cassette (to the index position).
- To keep the mandrels in horizontal position, remove the Screw and press the Pusher plunger against the inner tools of the Mandrel.

- Sleeve
- Mandrel
- Cassette
- Screw
- Pusher plunger
- Loosen the Screw.
- Set the Guide to the distance A. Make sure the Guide are centred around the Sleeve.
- Tighten the Screw.

A(mm) = 0.2
- Sleeve
- Screw
- Guide
Cutting Unit - Lubricate Vertical Cylinder
| Equipment Status | Program Step step zero |
| Special Equipment | Grease gun: TP No. 950926-0000 |
| Consumables | Grease: TP No. 344407-0000 |
- Use a Grease gun to lubricate the Vertical cylinder with grease.Note: During lubrication the Piston rod must be moved up and down.
- Stop lubricating when the grease is coming through the sealing.Note: Remove surplus lubrication.

- Grease gun
- Vertical cylinder
- Piston rod
Cutting Unit - Overhaul
| Equipment Status | Program Step step zero |
Stop Block
- Remove the Screw.
- Change the Stop block.
- Set the stop block, see Procedure Cutting Unit - Set Stop Block on page Cutting Unit - Set Stop Block.
- Tighten the Screw.

- Screw
- Stop block
Vertical Cylinder
- Measure the distance A for the Proximity switch, note the distance.
- Remove the Proximity switch.
- Disconnect the hoses from the Vertical cylinder.
- Remove the Screw and the Screw including the washers.Note: Be careful not to lose the Shim.
- Remove the Vertical cylinder.
- Remove the Flange by loosening the Screw and remove the Screw, with an allen key.
- Change the Vertical cylinder.
- Assemble in the reverse order.
- Set the distance A for the Proximity switch .
- Close both end position dampers completely by turning the Screw and the Screw in as far as they will go.
- Open the top position damper by turning the Screw out four turns.
- Open the bottom position damper by turning the Screw out 4 turn.
- Set the holder, see Procedure Cutting Unit - Set Vertical Cylinder on page Cutting Unit - Set Vertical Cylinder.

- Proximity switch
- Vertical cylinder
- Screw
- Screw
- Shim
- Flange
- Screw
- Screw
- Screw
- Screw
Cylinder and Link Head
- Remove the Protection cover.
- Remove the Nut and the Nut.
- Remove the Cylinder. Make sure that the Cylinder is in its end position, measure the distance B and note it.
- Loosen the Nut.
- Change the Link head and set the distance B.
- Assemble in the reverse order.Note: If there are any doubts regarding the movement for the Cylinder, see Procedure .

- Protection cover
- Nut
- Nut
- Cylinder
- Nut
- Link head
Bearings
- Remove the Protection cover, see illustration on previous page.
- Remove the Screw and lift out the Profile holder.Note: Take care of the Shim.
- Remove the Screw.
- Loosen the Screw and remove the Flange, crank and cylinder in one piece.
- Remove the Screw, the Washer, and the Profile.
- Remove the Retaining ring and change the Bearing on both sides of the Profile axle.
- Assemble the holder in the reverse order.

- Screw
- Shim
- Profile holder
- Screw
- Screw
- Flange
- Screw
- Washer
- Profile
- Retaining ring
- Bearing
- Profile axle
Cutting Unit - Check for Sprue
- Make sure that all sprue goes into the discharge tray Collecting box. If sprue is found outside the Collecting box above the LFU, check settings. See Procedure

- Collecting box
Alarms and Troubleshooting CS
Overview
Overview of the alarms in the Carton Section.| Pos. | Cross reference |
| 1 | 110302011 / 110312012, Material Web Slack, too Short |
| 2 | 110302031 / 110312032, Design Mark Read Error |
| 3 | 110302051 / 110312052, LS Oven, Wrong Vertical Position |
| 4 | 110302061 / 110312062, LS Oven, Preheating Time too Long |
| 5 | 110302071 / 110312072, LS Oven Strip Side, Wrong Temperature |
| 6 | 110302081 / 110312082, LS Oven no Strip Side, Preheating Time too Long |
| 7 | 110302091 / 110312092, LS Oven no Strip Side, Wrong Temperature |
| 8 | 110302311 / 110302321 / 110312311 / 110312322, Sleeve Missing |
| 9 | 110302141 / 110302151, Sleeve Unit Crash Mandrel 1:X |
| 10 | 110312142 / 110312152, Sleeve Unit Crash Mandrel 2:X |
| 11 | 110302301 / 110312302, Splice Sensor Error |
| 12 | 110302220, Air supply and Pressure to the Safety Valve |
110302011 / 110312012, Material Web Slack, too Short
Alarms and Troubleshoot Carton Section.DescriptionThe packaging material is feed through the ASU and then up to the cutting unit. The photocell T12B1207/T12B2207 monitors the packaging material slack.Condition for AlarmThe amount of slack is outside the alarm limits set in the PLC.- the production stops on the affected machine side. The machine side steps down to MOTOR RUNNING.
- the affected machine side stops cutting new blanks, but fills and finishes all the packages that are currently moving through that side.
- the affected machine side steps down to Tank Filling after 10 minutes.
- the unaffected machine side continues to run.
Troubleshooting110302031 / 110312032, Design Mark, Reading Error S1 / S2
Alarms and Troubleshoot Carton Section.DescriptionThe barcode reader detects the barcodes on the packaging material. The distance between the barcodes is measured and the volume is calculated.Condition for Alarm- The barcode reader does not detect any volume within the first 6.4 seconds.
- The barcode reader does not detect three barcodes in a row during production.
- The production stops on the affected machine side. The machine side steps down to MOTOR RUNNING.
- The affected machine side stops cutting new blanks, but fills and finishes all the packages that are currently moving through that side.
- The affected machine side steps down to Tank Filling after 10 minutes.
- The unaffected machine side continues to run.
TroubleshootingNote: Basic settings must be done according to MM.- Check the position of the photocells. See Procedure 7.10-3 TMCC2 - Set Photocells Manually, in the MM.
- Check the barcode reader. See Procedure 2.1.5-1 Supply Monitor- Set Photocell Receivers.
- The eye on the Bar code reader may be dirty. Clean the eye.
- There may be glitches in the electrical connections. Check the connections.
- The wheel/buttons on the Bar code reader may accidentally have been changed. Reset to correct settings.
- Check that the photocell colour setting is correct.
- Check the distance between the Bar code reader and the material web. Adjust if necessary.
- Check that the package material web is correctly pulled through the machine. See Procedure 3.4 Preparation after SIP, in the OM.
- Run with a different material or design.
- Check that the base 1000 Long or Short is chosen in the service menu.
- Is the Bar code reader loose? Fasten it, if necessary.
- If the material has certain decor that is in line with the Bar code mark, it can disturb the reading. It can help to move the Bar core reader a bit transversally.
- Is the Bar code reader correct positioned transversally to the material web? Adjust if necessary.
Cutting Unit
Alarms and Troubleshoot Carton Section.DescriptionThe barcode reader detects the barcodes on the packaging material. The distance between the barcodes is measured and the volume is calculated.Condition for Alarm- The barcode reader does not detect any volume within the first 6.4 seconds.
- The barcode reader does not detect three barcodes in a row during production.
- The production stops on the affected machine side. The machine side steps down to MOTOR RUNNING.
- The affected machine side stops cutting new blanks, but fills and finishes all the packages that are currently moving through that side.
- The affected machine side steps down to Tank Filling after 10 minutes.
- The unaffected machine side continues to run.
TroubleshootingNote: Basic settings must be done according to MM .- The counter roller may be in released position. Reset to enganged position.
- Adjust the excentric shaft to get correct pressure on the rubber wheel.
- Very cold web reels will get condensate, which may cause the rubber wheel to slip. Store the web reels in a warmer place.
- The rubber wheel may get flattened after longer stand still. Replace the rubber wheel. Always release the pressure during stand still.
- The rubber wheel may become worn out, rubber may have loosened, rubber may be dis-formed, etc. Replace the rubber wheel. Always release the pressure during stand still.
- Check that the web material guides are not set too tight. That can cause the rubber wheel to slip.
- The spring loaded counter bar in the cutting unit may be sticking. Check that the guides works, that the springs are working correct, etc.
- If the servo motor is not running, a reset of the servo drive is needed: Unplug the Sercos circuit, (fiber optic cable). Open and close one of the doors.
- Leaking cooling water hoses can drip on the material web. This may cause the roller to slip. Change the leaking hoses.
Pre-Folder
Alarms and Troubleshoot Carton Section.DescriptionThe barcode reader detects the barcodes on the packaging material. The distance between the barcodes is measured and the volume is calculated.Condition for Alarm- The barcode reader does not detect any volume within the first 6.4 seconds.
- The barcode reader does not detect three barcodes in a row during production.
- The production stops on the affected machine side. The machine side steps down to MOTOR RUNNING.
- The affected machine side stops cutting new blanks, but fills and finishes all the packages that are currently moving through that side.
- The affected machine side steps down to Tank Filling after 10 minutes.
- The unaffected machine side continues to run.
TroubleshootingNote: Basic settings must be done according to MM.- Ensure that the pre-folder is OK, and not touching the paper guide in upper position. The pre-folder shall be in correct position, both upper and down. Check that the crease is made in the correct position.
- Is the Pre-folder cylinder functioning correct? Check movement during production. (Temporary disengage.) Check cylinder, check pilot valve, check for leakage in pilot valve assembly, check pneumatic connections, check correct assembly with template.
Other
Alarms and Troubleshoot Carton Section.DescriptionThe barcode reader detects the barcodes on the packaging material. The distance between the barcodes is measured and the volume is calculated.Condition for Alarm- The barcode reader does not detect any volume within the first 6.4 seconds.
- The barcode reader does not detect three barcodes in a row during production.
- The production stops on the affected machine side. The machine side steps down to MOTOR RUNNING.
- The affected machine side stops cutting new blanks, but fills and finishes all the packages that are currently moving through that side.
- The affected machine side steps down to Tank Filling after 10 minutes.
- The unaffected machine side continues to run.
TroubleshootingNote: Basic settings must be done according to MM.- Check that the slack is long enough at start-up and at web splices. If not, the rubber wheel might slip.
- It can help to remove the TMCC card, and put it back.
- Are the web splices OK? If the manual preparation for packaging material splice is not correct: Ensure that the splice is prepared correct acc to OM. Ensure that alignment between the webs are correct. See setting instruction in MM.
- The motor for the slack may be wrong connected. Correct connection is D connection.
- Check that no oil has leaked into the slack motor.
110302051 / 110312052, LS Oven, Wrong Vertical Position
Alarms and Troubleshoot Carton Section.DescriptionThe cylinder T21M1231/T21M2231 moves the LS oven into product position. The sensor T21B1214/T21B2214 detects when the LS oven is in place.Condition for AlarmThe machine side is in step PRODUCTION or PRODUCTION END, but the oven is not in production position.- the production stops on the affected machine side. The machine side steps down to MOTOR RUNNING.
- the affected machine side stops cutting new blanks, but fills and finishes all the packages that are currently moving through that side.
- the affected machine side steps down to Tank Filling after 10 minutes.
- the unaffected machine side continues to run.
Troubleshooting- Check that the sensor registers the production position of the oven.
- Check the movement of the cylinder. See Procedure 2.3.2-1 Bracket LS - Set Bracket, in the MM.Note: When setting the speed for lifting the oven, make sure the movement is smooth and controlled. Too high speed damages the heating element.
110302061 / 110312062, LS Oven, Preheating Time too Long
Alarms and Troubleshoot Carton Section.DescriptionThe heating cartridge T21E1201/T21E1202 heats up the LS oven. The thermocouple T21B1203/T21B1204 measures the temperature.Condition for AlarmThe temperature is outside the limits set in the PLC in step pre-heating.- the production stops on the affected machine side. The machine side steps down to MOTOR RUNNING.
- the affected machine side stops cutting new blanks, but fills and finishes all the packages that are currently moving through that side.
- the affected machine side steps down to Tank Filling after 10 minutes.
- the unaffected machine side continues to run.
Troubleshooting- The alarm can be triggered if the machine, in operating temperature, is stepped down below step HEATING, and then up to HEATING or higher again. Step up to HEATING and wait 5minutes before any actions are taken.
- Check the heater element and change if necessary. See Procedure 2.3.1-1 LS-Heater - Check Element (Heating Cartridge) and 1.3.2.5-6 Heater - Change Elements, in the MM.
- Check the air supply.
- Check the thermocouple and change if necessary. See Procedure 2.3.1-4 LS-Heater - Change Thermocouple, in the MM.
- Check that the wire is not broken or incorrectly connected. If the wire is broken, the value on the TPOP will show 1372°C.
110302071 / 110312072, LS Oven, Strip Side, Wrong Temperature
Alarms and Troubleshoot Carton Section.DescriptionThere is a delay of 10minutes in the PLC logic program after the machine is stepped up to pre-heating.Condition for AlarmThe temperature is outside the limits set in the PLC.- the production stops on the affected machine side. The machine side steps down to MOTOR RUNNING.
- the affected machine side stops cutting new blanks, but fills and finishes all the packages that are currently moving through that side.
- the affected machine side steps down to Tank Filling after 10 minutes.
- the unaffected machine side continues to run.
Troubleshooting110302081 / 110312082, LS Oven, no Strip Side, Preheating Time too Long
Alarms and Troubleshoot Carton Section.DescriptionThere is a delay of 10minutes in the PLC logic program after the machine is stepped up to pre-heating.Condition for AlarmThe temperature is outside the limits set in the PLC.- the production stops on the affected machine side. The machine side steps down to MOTOR RUNNING.
- the affected machine side stops cutting new blanks, but fills and finishes all the packages that are currently moving through that side.
- the affected machine side steps down to Tank Filling after 10 minutes.
- the unaffected machine side continues to run.
Troubleshooting- The alarm can be triggered if the machine, in operating temperature, is stepped down below step HEATING, and then up to HEATING or higher again. Step up to HEATING and wait 5minutes before any actions are taken.
- Check the heater element and change if necessary. See Procedure 2.3.1-1 LS-Heater - Check Element (Heating Cartridge) and 1.3.2.5-6 Heater - Change Elements, in the MM.
- Check the air supply.
- Check the thermocouple and change if necessary. See Procedure 2.3.1-4 LS-Heater - Change Thermocouple, in the MM.
- Check that the wire is not broken or incorrectly connected. If the wire is broken, the value on the TPOP will show 1372°C.
- Check the connection terminal and change if necessary.
110302091 / 110312092, LS Oven, no Strip Side, Wrong Temperature
Alarms and Troubleshoot Carton Section.DescriptionThere is a delay of 10minutes in the PLC logic program after the machine is stepped up to pre-heating.Condition for AlarmThe temperature is outside the limits set in the PLC.- the production stops on the affected machine side. The machine side steps down to MOTOR RUNNING.
- the affected machine side stops cutting new blanks, but fills and finishes all the packages that are currently moving through that side.
- the affected machine side steps down to Tank Filling after 10 minutes.
- the unaffected machine side continues to run.
Troubleshooting110302311 / 110302321 / 110312311 / 110312322, Sleeve Missing
Alarms and Troubleshoot Carton Section.DescriptionOptical sensors detect sleeves leaving the erector boxes.Condition for AlarmThe photocell beam is not broken at the MSP 560 to 650.- the production stops on the affected machine side.
- the affected machine side stops cutting new blanks, but fills and finishes all the packages that are currently in the package section.
- the unaffected machine side continues to run.
Troubleshooting- Check the photocell.
- Check MSP between the TPOP and the curve unit.
- Check blanks and sleeves.
- Check the distributor arm settings. See Procedure 2.6.4-2 Distributor Drive - Set Timing Belt, in the MM.
- Check the side feeder settings. See Procedure 2.5-2 Side Feeder – Set, in the MM.
110302141 / 110302151, Sleeve Unit Crash, Mandrel 1:X
Alarms and Troubleshoot Carton Section.DescriptionThe sleeves are erected from the erector boxes and pushed on to the mandrels by the pushers.Condition for AlarmThe photocell T21B3205/T21B4205 detects an obstacle between MSP1175-1300 during step MOTOR RUNNING, PRODUCTION, or PRODUCTION END.- the production stops on the affected machine side.
- the affected machine side stops cutting new blanks, but fills and finishes all the packages that are currently in the package section.
- the unaffected machine side continues to run.
Troubleshooting110302142/110302152, Sleeve Unit Crash, Mandrel 2:X
Alarms and Troubleshoot Carton Section.DescriptionThe sleeves are erected from the erector boxes and pushed on to the mandrels by the pushers.Condition for AlarmThe photocell T21B5205/T21B6205 detects an obstacle between MSP1175-1300 during step MOTOR RUNNING, PRODUCTION, or PRODUCTION END.- the production stops on the affected machine side.
- the affected machine side stops cutting new blanks, but fills and finishes all the packages that are currently in the package section.
- the unaffected machine side continues to run.
Troubleshooting110302301 / 110312302, Splice Sensor, Error
Alarms and Troubleshoot Carton Section.DescriptionThe splice sensors T12B1211/T12B2211 detect the splicing of packaging material.Condition for AlarmThe splice sensor does not register a new splice within 45 seconds.- the production stops on the affected machine side. The machine side steps down to MOTOR RUNNING.
- the affected machine side stops cutting new blanks, but fills and finishes all the packages that are currently moving through that side.
- the affected machine side steps down to Tank Filling after 10 minutes.
- the unaffected machine side continues to run.
Troubleshooting110302220, Air supply and Pressure to the Safety Valve
Troubleshooting- Make sure that the air pressure is set correctly on the main ramp. See Procedure Pneumatic Supply - Set Pressure.
- Make sure that the manual valve before the safety valve is open. See Procedure Safety Air Valve - Description.
- Make sure that the manometer on the safety air valve shows at least 6bar. If it shows < 3bar, there is an air leakage problem, and the safety air valve will not fully pressurise the system. Check for air leakage.
- If the safety air valve shows 6 bar, there should be a signal to the PLC system from the pressure guard. Check the electrical connection to the pressure guard and the Point I/O input. The pressure guard is factory set and should normally not be adjusted.
Functional Description
There are three versions of the SRU for the Tetra Top machine.The following table describes which type of package openings the three types relates to.| Version | Opening | |
| SRU Micro | Micro Lokka |  |
|
| SRU Version 1 | Mini Taishan A38 |  |
| SRU Version 2 | MiniV Nallo A38Mini Taishan A38Mini SaromaMidi HuronMidi Idum A38 |  |
Functional Description
The sprue remover is placed on the conveyor and removes the sprue from the top of the packages before the cap is assembled. A belt brake is used to transport the package in the conveyor direction and support the package through the sprue remover.With a Belt and a Wheel, the sprue remover pulls the sprue perpendicular to the movement direction of the Package. The sprue is pulled off, transported to the drop chute and gathered in the collection box on the side of the sprue remover.
- Belt
- Wheel
- Package
Sprue Remover - Set Position
| Equipment Status | Power must be turn OFF. Program Step Program Step |
- Loosen the Screw to remove the Protective cover.

- Screw
- Protective cover
- Make sure that the sprue remover Foot are leveled. The distance A, between the Conveyor and the Fastening plate, must be equal on both sides of the sprue remover.

A = A
- Conveyor
- Fastening plate
- Set the distance B, between the opening in the Fastening plate and the Conveyor. Adjust with the Angle bracket.
- Conveyor
- Fastening plate
- Angle bracket
- Use a Package as a template to set the distance C, between the top of the Package and the Protection plate. Place the Package between the belts, just before the sprue enters the top belt and the rubber wheel.
- Use several packages to find an average height.

C = 1 to 2.5 mm
- Package
- Protection plate
Movimot - Check Settings
Check the settings on MOVIMOT.- Remove the lid and check that the Potentiometer f1 is in position 10.
- The Potentiometer f2 should be in position 2.
- The Potentiometer t1 should be in position 0.
- The Switch DIP 1/7 should be in position ON.

- Potentiometer f1
- Potentiometer f2
- Potentiometer t1
- Switch DIP 1/7
Brake Plate - Set Brake Belt Width
| Equipment Status | Power must be turn OFF. Program Step Program Step |
This instruction must be performed on the side of the SRU where the sprue chute is installed. This is the only adjustable side.- Remove the protective covers.
- Loosen the Screw to release the belt tension.

- Screw
- Loosen the Screw and the Screw.
- Loosen the Screw.
- Place a package between the Brake belt and adjust the width.Note: Use more than one package.
- Check that the Brake belt do not cause dents on the packages.
- Tighten the Screw, the Screw, and the Screw.

- Screw
- Screw
- Screw
- Brake belt
- Set the brake belt tension with the Screw.
- Centre the SRU in relation to the conveyor.
- Make sure that the knife wheels are centred to the sprue/package position. If necessary, set the position. See Procedure Cutting Unit - Set.
- Assemble the protective covers.

- Screw
Brake Plate - Set Belt Tension
| Equipment Status | Power must be turn OFF. Program Step Program Step |
To set the belt tension:- Loosen the Roll.
- Drag out the belt according to the arrow.
- Adjust the tension of the belt with the Roll.
- When the belt can move 5 mm to 8 mm at the drag point, tighten the Roll.

- Roll
Brake Plate - Change Sliding Strips
| Equipment Status | Power must be turn OFF. Program Step Program Step |
| Special Equipment | Ruler |
| Consumables | Thread locker, TP No. 351532-0000 |
- Remove the brake belts. See Procedure Brake Plate - Change Brake Belt.
- Remove the Screw.
- Change the Sliding strip.
- Apply thread locker on the Screw and tighten them.
- Check with a ruler that the Sliding strip are aligned with the two outer Roller. If necessary, adjust the Sliding strip.
- Assemble in the reverse order.

- Screw
- Sliding strip
- Roller
Cutting Unit - Set Belt Tension
| Equipment Status | Power must be turn OFF. Program Step Program Step |
| Special Equipment | Tension meter TP No. 90609-7425 |
- Use a Belt tension meter to measure the belt tension at the arrow.
- Loosen the Flange nut.
- Adjust the tension of the belt with the tension roller.
To set the belt tension:- Make sure that the belt has a frequency between 80 to 130 Hz.

- Belt tension meter
- Flange nut
Cutting Unit - Set Wheels
| Equipment Status | Power must be turn OFF. Program Step Program Step |
- Remove the protective cover.
- Loosen Screw.
- Set distance A between the wheels.
- Tighten Screw.
- Set the belt tension. See Procedure Cutting Unit - Set Belt Tension.

A = 148.5 ± 0.1 mm
- Screw
Drive Unit - Change Timing Belt
| Equipment Status | Power must be turn OFF. Program Step Program Step |
Depending on the installation, the box holder may need to be removed to perform this procedure.- Remove the Screw and the Cover panel.
- Loosen the Screw to release the belt tension.
- Change the Timing belt.
- Tighten the belt tension.
- Put back the Cover panel.

- Screw
- Cover panel
- Screw
- Timing belt
Drive Unit - Check Bearing
| Equipment Status | Power must be turn OFF. Program Step Program Step |
| Special Equipment | Stethoscope |
Risk of burns.During production the motor gets hot. Do not touch the motor.
- Remove the four Screw to remove the Motor cover.
- Check the condition of the Bearing. Use a motor stethoscope.
- If necessary, change the Motor.

- Screw
- Motor cover
- Bearing
- Motor
Functional Description
The sprue remover unit is placed on the conveyor and removes the sprue from the top of the packages before the cap is assembled. A belt brake is used to transport the package in the conveyor direction and support the package through the sprue remover unit.With a Belt and a Wheel, the sprue remover unit pulls the sprue perpendicular to the movement direction of the package. The sprue is pulled off, transported to the drop chute, and gathered in the collection box at the outfeed side of the sprue remover unit.For a description of other types of Sprue removers, see Functional Description.
- Belt
- Wheel
- Package
Belt Drive - Check Timing Belt Tension
| Equipment Status | Power must be turn OFF. Program Step offProgram Step |
| Special Equipment | Belt tension meter TP No. 90459-2181 |
Remove the covers according to Covers - Remove Protective Covers.Use the tension meter to measure the belt tension in the middle part of the Drive belt, between the two Adjusting roller.- To avoid any misreading due to hand movement, hold the tension meter close to the static belt section.
- Hold the probe a few millimetres above or below the belt, at the Measuring point.
- To make the belt vibrate, lightly hit the belt with, for example, the grasp end of a screwdriver.
- The red dot in the display lights up in response to the belt frequency.
- When a measurement is obtained, the device beeps and displays the frequency of vibration in Hertz.
- If the tension is below the tolerance range set the tension according to Belt Drive - Set Timing Belt Tension.
- Install the covers.

- Drive belt
- Adjusting roller
- Measuring point
Belt Drive - Check Timing Belt Condition
| Equipment Status | Power must be turn OFF. Program Step Program Step off |
- Check the Timing belt for cracks. The steel cord must not be visible.
- Check that edges of the Timing belt are not worn or frayed.
- Check that the Timing belt is not unbalanced. If the Belt tooth is unbalanced, that is, not equilateral, then the belt is worn out. It could be that the belt tension has been too high.
- If necessary, change the Timing belt according to Belt Drive - Change Timing Belt.

- Timing belt
- Belt tooth
Belt Drive - Set Timing Belt Tension
| Equipment Status | Power must be turn OFF. Program Step Program Step |
| Special Equipment | Belt tension meter TP No. 90459-2181 |
Note: Never use the front adjusting roller to set the belt tension.- Check the tension of the timing belt according to procedure Belt Drive - Check Timing Belt Tension. If necessary, set the timing belt.
- Loosen the Screw.
- Increase the belt tension with the Axle pin, turning the screw to the right.
- Tighten the Screw.
- Measure the belt tension. The tolerance range should be 60±5Hz.Note: It is important that the Screw are tightened when measuring the belt tension. Otherwise the frequency will be different.
- Repeat the items Reference to Reference, until the tension value is within the tolerance limits.

- Screw
- Axle pin
Belt Drive - Set Movimot Settings
| Equipment Status | Power must be turn OFF. Program Step off |
To check the settings on the MOVIMOT, follow the instructions below.
- Remove the Small lid. Make sure that Potentiometer f1 is in position 10.

- Small lid
- Potentiometer f1
- Remove the Screw and remove the Main lid.
- Make sure that Potentiometer f2 is in position 2.
- Make sure that Potentiometer t1 is in position 0.

- Screw
- Main lid
- Potentiometer f2
- Potentiometer t1
- Make sure that the DIP switch setting S1 are in position ON.
- Make sure that the DIP switch setting S2 are in position ON.

- DIP switch setting S1
- DIP switch setting S2
Height Adjustment - Forced Homing
Note: Forced homing can be done as long as the TT/3 filling machine is not in machine step PRODUCTION or PRODUCTION END.- Hold the Down button and the ON button for 3 seconds.Note: During homing the green lamp will blink. Note: Forced homing is necessary when installing the SRU for the first time, and if for example, a power outage happens in the filling machine.

- ON button
- Down button
- Let the stepper motor run until it stops.Note: The green lamp stops blinking when the right position is found.Note: The SRU stops at the given height for the chosen top shape and volume after a completed homing.
Height Adjustment - Check and Set Distance between Belt and Knife Wheel
| Equipment Status | Power must be turn OFF. Program Step offProgram Step |
| Area | Pass criteria |
| Distance B | B = A |
- Measure the sleeve of the package.
- The distance between the top of the Belt and the bottom of the Wheel should be equal to the distance A.
- Adjust with Spacer disc on both sides if necessary. See arrow for location.

- Belt
- Knife wheel
- Spacer disc
Height Adjustment - Check and Set Distance between Belt and Wheel
| Equipment Status | Power must be turn OFF. Program Step offProgram Step |
Preparations
- Check the total number (n1+n5) of Spacer Disc installed on the sprue remover. See the table for the correct number of installed discs. Number n1 for discs with a thickness of 1 mm and n5 for discs with a thickness of 5 mm.
| Opening | n1 | n5 |
| MiniV Nallo A38 | 5 | 3 |
| Mini Taishan A38 | 5 | 3 |
| Mini Saroma | 5 | 0 |
| Midi Huron | 5 | 1 |
| Midi Idum A38 | 5 | 1 |

- Spacer Disc
- Valid for: MiniV Nallo A38Valid for: Mini Taishan A38Make sure that the Knife Wheel are installed.
- Valid for: Mini SaromaValid for: Midi HuronValid for: Midi Idum A38Make sure that the Knife Wheel are not installed.

- Knife Wheel
Measure and Set
Not valid for: Midi Huron- Measure distance A on the top of the package.
- Set distance B equal to distance A (B = A).Note: The distance B is measured between the top of the Belt and the bottom of the Wheel.
- If necessary, adjust on both sides the distance B, using 1 mm thick Spacer Disc. See the arrows.

- Spacer Disc
- Belt
- Wheel
Height Adjustment - Check and Set Height to Wheel
| Equipment Status | Power must be turn ON.
|
Preparations
- Valid for: MiniV Nallo A38Valid for: Mini Taishan A38Make sure that the Knife Wheel are installed.
- Valid for: Mini SaromaValid for: Midi HuronValid for: Midi Idum A38Make sure that the Knife Wheel are not installed.

- Knife Wheel
Set Height
| Opening | A (mm) |
| MiniV Nallo A38 | 4 ±1 |
| Mini Taishan A38 | 4 ±1 |
| Mini Saroma | 3 ±1 |
| Midi Huron | 4 ±1 |
| Midi Idum A38 | 4 ±1 |
- Check that the machine is
not in step PRODUCTION or PRODUCTION END.Note: The height adjustment can only be made when the packaging machine is not in step PRODUCTION or PRODUCTION END.
- To start height adjustment, press the Up button, and keep it pressed for 3 seconds.Note: When height adjustment is activated, the green lamp on the indicating tower starts to blink and the belts stops.
- Put a Package as a template between the Belt, right before the Sprue enters the Wheel and the Belt.
- Measure the distance A, between the Package top and the bottom of the Wheel.Note: Use several packages to find an average distance.
- If the distance A is out-of-specification, adjust the height by pressing the Down button or the Up button.Note: One press of the button is equivalent to 0.5-mm movement in height.
- To deactivate the height adjustment and to start the machine, press the On button, and keep it pressed for 3 seconds. The green lamp stops blinking.
- Save the adjusted height to the recipe. See 6.2 Change Product in the OM.

- Package
- Package top
- Wheel
- Belt
- Sprue
- Belt
- On button
- Down button
- Up button
Valid for: Midi Huron- On Midi Huron machines, the distance A is measured to the highest point of the package.
Brake Unit - Width Adjustment
| Equipment Status | Power must be turn OFF. Program Step offProgram Step |
- Valid for: MiniV Nallo A38Valid for: Mini Taishan A38Valid for: Mini SaromaValid for: Midi Idum A38Measure and note the width A at the top of the package.
- Valid for: Midi HuronMeasure and note the width A at the widest part of the package.
- Remove the covers according to Covers - Remove Protective Covers.
- Check that the distance B is the same on both sides. Adjust if not.
- Loosen the two Screw on the cutting unit.
- Turn the Bandwidth Screw to adjust the width C between the drive belts so that the width C = A-D. See table for the values on D.
| Opening | D (mm) |
| MiniV Nallo A38 | 2 |
| Mini Taishan A38 | 2 |
| Mini Saroma | 1 |
| Midi Huron | 1 |
| Midi Idum A38 | 0 |
- Make sure that the packages can pass through the machine without any problems.Note: The package must be kept stable, but there must not be any marks on the package.
- Tighten the Screw.
- Assemble the covers in the reverse order.

- Screw
- Bandwidth Screw
Cutting Unit - Centre
| Equipment Status | Power must be turn OFF. Program Step Program Step |
- Remove the covers according to Covers - Remove Protective Covers.
- Use a package as a template to centre the Cutting unit.
- Loosen the Screw and adjust the position of the Cutting unit. The sprue on the package should be centred between the wheels.Note: Use several packages.
- Tighten the Screw.
- Install the covers.

- Screw
- Cutting unit
Cutting Unit - Check Timing Belt Tension
| Equipment Status | Power must be turn OFF. Program Step offProgram Step |
| Special Equipment | Belt tension meter TP No. 90459-2181 |
| Opening | f (Hz) |
| MiniV Nallo A38 | 90 ±5 |
| Mini Taishan A38 | 90 ±5 |
| MIni Saroma | 130 ±5 |
| Midi Huron | 130 ±5 |
| Midi Idum A38 | 90 ±5 |
- Remove the covers. See Procedure Covers - Remove Protective Covers.
- Use the belt tension meter to measure the natural frequency (f) of the tensioned belt. See the table.Note: The belt tension is proportional to the natural frequency squared.Note: To avoid any misreading due to hand movement, hold the tension meter close to the static belt section.
- Hold the sensor probe at the Measuring point, in the centre of the free span. Hold at a distance of a few millimetres away from the top or bottom surface of the belt.
- To make the belt vibrate, hit the belt lightly with, for example, the grip end of a screwdriver.
- The red light dot in the display lights in response to the belt frequency.
- When an approved measurement is reached, the belt tension meter emits an acoustic signal and displays the measured frequency on the equipment screen.
- If the measured frequency is outside the tolerance range set the belt tension. See Procedure Cutting Unit - Set Belt Tension.
- Install the covers.

- Measuring point
Cutting Unit - Check Timing Belt Condition
| Equipment Status | Power must be turn OFF. Program Step offProgram Step |
- Remove the covers according to Covers - Remove Protective Covers.
- Check the Timing belt for cracks. The steel cord must not be visible.
- Check that edges of the Timing belt are not worn or frayed.
- Check that the Timing belt is not unbalanced. If the Belt tooth is unbalanced, that is, not equilateral, then the belt is worn out. It could be that the belt tension has been too high.
- If necessary, change the Timing belt according to Cutting Unit - Change Timing Belt.
- Install the covers.

- Timing belt
- Belt tooth
Cutting Unit - Change Timing Belt
| Equipment Status | Power must be turn OFF. Program Step offProgram Step |
- Remove the covers. See Procedure Covers - Remove Protective Covers.
- To release the belt tension, loosen the Screw.
- To remove the scrape, loosen the Screw.
- Loosen the Screw and separate the Wheel.
- Remove the Timing belt.
- Install the new timing belt.

- Screw
- Screw
- Screw
- Timing belt
- Wheel
- Set the distance between the knife wheels. See table for the respective package opening type and corresponding Procedure in the MM.
| Opening | Procedure in MM |
| MiniV Nallo A38Mini Taishan A38Midi Idum A38 | 2.14.3.3-10 Cutting Unit - Check and Set Knife Wheels |
| Mini SaromaMidi Huron | 2.14.3.3-11 Cutting Unit - Check and Set Wheels |
- Set the belt tension. See Procedure Cutting Unit - Set Belt Tension.
- Assemble the scrapers with the Screw.
- Adjust the scrapers so that they are 0.5 mm away from the belt.Note: Ensure that the belt does not touch the scraper during production.
- Tighten the Screw.
- Install the covers.
Cutting Unit - Set Belt Tension
| Equipment Status | Power must be turn OFF. Program Step offProgram Step |
- Remove the covers. See Procedure Covers - Remove Protective Covers.
- Check the belt tension. See Procedure Cutting Unit - Check Timing Belt Tension.
- If necessary, set the belt tension.
- Loosen the Screw.
- Increase the belt tension by turning the Screw to the right.
- Tighten the Screw.
- To reduce the slack, pull hard a few times on the belt, at the measuring point.
- Check the belt tension. See item b).
- If the belt tension is not correct, repeat the items Reference to Reference.
- Install the covers.

- Screw
- Screw
Cutting Unit - Check Knife Wheels
| Equipment Status | Power must be turn OFF. Program Step offProgram Step |
- Remove the covers according to Covers - Remove Protective Covers.
- Check that the Knife wheels are running levelled to each other with a steel ruler. Look for damage on the sharp edges.
- Install the covers.

- Knife wheels
Covers - Remove Protective Covers
| Equipment Status | Power must be turn OFF. Program Step off |
- Loosen the Screw and lift off the Protective cover.

- Screw
- Protective cover
Covers - Check Spacers
| Equipment Status | Power must be turn OFF. Program Step off |
- Check that correct number (n) of Spacer with a thickness of 5 mm have been installed under the covers.
| Opening | n |
| MiniV Nallo A38 | 0 |
| Mini Taishan A38 | 0 |
| Mini Saroma | 3 |
| Midi Huron | 2 |
| Midi Idum A38 | 2 |

- Spacer
Pneumatic System - Set Air Pressure
- Turn the Knob to adjust the air pressure.
- Read the air pressure value on the Manometer.
- Set the air pressure to 2 to 3bar.

- Knob
- Manometer
Pneumatic System - Change Filter
| Equipment Status | Air must be turn OFF. Program Step offProgram Step |
Risk of personal injury.Pressurised machinery. The system must be depressurised before cleaning.
- Shut off the air supply by turning off the Shut-off valve.

- Shut-off valve
- Press the Button on the Filter bowl downwards.
- Turn the Filter bowl to the left, and pull it gently downwards.

- Button
- Filter bowl
- Turn the Filter plate to the left.
- Remove the Filter plate and the Filter.
Risk of damage to the equipment.A cleaned filter gets clogged more quickly than a new filter. It is recommended to change the filter instead of cleaning it.
Change the filter or clean it with water (max. 60 °C (140 °F)), soap suds, or petroleum ether (free of compounds). Note: Only hold the clean filter at the lower end.- Attach the Filter plate and the Filter , and turn it to the right.
- Attach the Filter bowl. Make sure that the Locking pin points towards the large Recess in the housing.
Risk of personal injury.Pressurised machinery. The filter bowl must be turned fully to the right into the body before pressurising the unit.
Turn the Filter bowl to the right until you hear a clicking sound.
- Filter bowl
- Filter plate
- Filter
- Locking pin
- Recess
Waste Pipe - Check Spacers
| Equipment Status | Power must be turn OFF. Program Step off |
- Check that the correct number (n) of Screw with a thickness of 5 mm has been installed under the brackets of the waste pipe.
| Opening | n |
| MiniV Nallo A38 | 2 |
| Mini Taishan A38 | 2 |
| Mini Saroma | 0 |
| Midi Huron | 0 |
| Midi Idum A38 | 0 |

- Spacer
Set Guides
| Equipment Status | Power must be turn OFF. Program Step off |
- Loosen the four Screw.

- Screw
- Take a few packages as samples. Measure the bottom of the packages for the widest measurement.
- Set the distance between the guides so that it is a wide as the largest bottom measure +0.5 mm. Tighten the four Screw.

- Screw
- Make sure that the guides are centred in comparison to the belts.

A=B
C=D
Digital Multi Circuit Protector - Set
| Equipment Status | Program Step step Zero |

| Number | Name | Function |
| 1 | Power input terminals (+V), (-V) | Connects to the input line. |
| 2 | Branch output terminals (+V), (-V) | Connects to the load lines.Up to four branch outputs can be connected. |
| 3 | Status indicators (red, green) | Indicates the connection and cut off status for each branch output.Cut off: Red. Connected: Green. |
| 4 | Tripping alarm output (+, -) | Output (transistor: OFF) when the error tripping operation functions. * |
| 5 | Alarm output (+. -) | Output (transistor: OFF) when a set value alarm detection is exceeded. * |
| 6 | Over-temperature output (+, -) | Output (transistor: OFF) when a set value for over-temperature detection is exceeded. * |
| 7 | External tripping input (+, -) | The tripping operation can be executed with an external input signal. |
| 8 | Seven-segment display (red) | Displays measured values and set values. |
| 9 | Unit indicators (orange) | V | Lit when the input voltage is being displayed. |
| A | Lit when the input current is being displayed.Flashes when the peak output current is being displayed. |
| kh | Lit when the run time is being displayed. |
| °C | Lit when the temperature is being displayed. |
| s | Lit when setting the sequence time. |
| 1 to 4 | Lit or flashing when displaying the branch output information. ** |
| 10 | Mode key | Used to change the parameter being displayed or to reset the peak hold current value. |
| 11 | Up key | Used to move to different setting modes or to increase a set value. |
| 12 | Down key | Used to move to different setting modes or to decrease a set value. |
| 13 | Reset key | Used when connecting branch outputs for tripping operations. *** |
| 14 | Communications terminals (RD, SD, SG) | Connects to the communication lines. (PS-232C). |
* Configured from independent circuits and either sinking or sourcing applications are possible.** Indicators 1 to 4 will not light exept when current is being displayed.*** Press for at least 3 s to enable operation.Note: The setting range is 0.5 to 3.8 A and the default value is 3.8. This default value must not be changed. The multi circuit protector is only meant for a 24 V DV load outside the main electrical cabinet and on the machine.Note: The first time that a multi circuit protector is connected it will enter the setting mode.- Press and hold the Up key and the down key at the same time for threeseconds to enter the mode selection menu.
- Use the Up key to step to Test Mode.
- Use the mode key to enter the Test Mode.
- Use the Up key and down key to select all four outputs.
- Use the mode key to set all the outputs to the ON position.
- Make sure that all four status indicators light up in green.
- Press and hold the Up key and the down key at the same time for threeseconds to enter the mode selection menu.
- Use the Up key to step to Run mode.
- Use the mode key to enter the Run mode.
TT/3 Machine Settings in the HMI
| Equipment Status | Program Step Step Zero |
Preparations
- Step the TT/3 filling machine down to step zero and make sure that the machine is ready to step up to Air on.
- Open the Operator panel door.
- Connect a keyboard to one of the USB port on the display unit of the TT/3 filling machine.
- Press F4 on the keyboard.

- Operator panel door
- USB port
Main
- Press
Main.Note: If the screen below does not open, press anywhere on the screen and then press F4 again.
- To change the
Main settings in the items that follow, use Increase and Decrease. - Press Go to submenu.

IncreaseDecrease
- Set Sprue Remover to YES or NO.
- Set Top Shape.
- Set Screw Cap.
- Set Magnetic design reader to YES or NO.

Sprue RemoverTop ShapeScrew Cap- Magnetic design reader
Rockwell ADN Point I/O - Set
| Equipment Status | Air must be turn ON.
|
- Make sure that the electrical supply disconnecting device for the SRU is in position I (ON).
- Check the MAC Address, printed on a label of the ethernet device in the electrical cabinet for the sprue remover unit.
- Double-click on the same MAC Address in the BOOTP/DHCP
Request History panel. 
- MAC Address
- MAC Address
- Type in the IP address in the IP Address field.
- 10.255.1.31 for the sprue remover unit connected to S1.
- 10.255.1.32 for the sprue remover unit connected to S2.
- Click
OK. 
- IP Address field
- Right click on the item just added in the Relation List and click
Disable BOOTP/DHCP.Note: Make sure that the message in the Status does not contain any errors. - Cycle the power on the electrical cabinet of the sprue remover unit.

- Relation List
- Status
- If necessary, reset to the factory defaults by setting the Thumb wheel to 888 and cycle the power to the adapter.
- Set the Thumb wheel back to 999 and cycle the power again. The DHCP (BootP) requests are shown on the network.Note: Do not forget to disable DHCP (BootP), or else the address is lost on the next power cycle.

- Thumb wheel
Ethernet TCP/IP Bus Coupler - Set
| Equipment Status | Power must be turn ON.
|
- Switch on all of the Address selector.
- Connect a computer to the ethernet TCP/IP bus coupler.

- Address selector
- Open the
Start menu on the PC and select Programs, Rockwell software, BOOTP-DHCP server and then BOOTP-DHCP server. 
ProgramsRockwell softwareBOOTP-DHCP serverBOOTP-DHCP server
Note: If it is the first time the BOOT DHCP Server program is used, a network setting will be requested. Otherwise continue with step .- Enter 255.255.0.0 as the Subnet Mask. All other settings should be set to zero.
- Select the OK button.

Subnet Mask OK button
- When the MAC address appears in the Request history window, MAC address display of the BOOT/DHCP server window, check that the same address is displayed on the Ethernet module and select the New button to begin the conversion from the MAC address to an IP address.
- When the MAC address appears in the Relation List window, select the MAC address.

BOOT/DHCP server windowRequest history window, MAC address displayNew buttonRelation List window
- Enter the new IP address in the IP address field of the New entry window according to the electrical manual.
- Select the OK button. The new IP address will appear in the Request history window, MAC address display.
- Select the Ethernet/IP module in the Relation List window and then select the Disable BOOTP/DHCP button.
- After the Ethernet/IP module has been configured, check that the correct IP address appears on the display on the Ethernet/IP module.
- Disconnect the PC.

- Request history window, MAC address display
- Relation List window
None fieldNone fieldNew entry window- OK button
Disable button
Alarms and Troubleshooting SRU
201330011/201330012 - Sprue Remover - Power error, S1/S2
DescriptionThe Sprue Remover unit removes the sprue from the top of the packages before the cap is assembled. The alarm prevents the Filling Machine from producing packages if the Sprue Remover unit is switched OFF.Conditions to set the alarmThe machine side is in step PRODUCTION or PRODUCTION END but the Sprue Remover unit is switched OFF.Troubleshooting- Check that the Sprue Remover unit is ON or turn it ON. To turn it on see 2.3.3 SRU Control Panel in the OM.
- Check the emergency stops and reset if needed. See 7.1 Emergency Stop in OM.
- Check the fuses.
201330021/201330022 - Sprue Remover - Height Adjustment Error - S1/S2
DescriptionThe height of the sprue remover belt can be adjusted to ensure that the sprue is removed. The alarm prevents the Filling Machine from producing packages when the Height Adjustment is activated from the Sprue Remover unit.Conditions to set the alarmThe machine side is in step AIR ON, HEATING, tank filling or MOTOR RUNNING and the height adjustment of the sprue remover belt is active.Troubleshooting- Finish the height adjustment. To do a height adjustment see Height Adjustment in the MM.
201330031/201330032 - Sprue Remover - Forced Homing active - S1/S2
DescriptionA homing is necessary when installing the Sprue Remover unit as an initialization run to get the actual height of the sprue remover belt and, for example, if an outage happens in the filling machine. The homing function is activated but not completed. The alarm prevents the Filling Machine from producing packages if the Sprue Remover is preforming a Homing.Conditions to set the alarmThe Filling Machine is in step AIR ON, HEATING, TANK FILLING or MOTOR RUNNING and the Sprue Remover unit is performing a homing.Troubleshooting201330041/201330042 - Sprue Remover - Forced Homing Not Completed, S1/S2
DescriptionA homing is necessary when installing the Sprue Remover unit as an initialization run to get the actual height of the sprue remover belt and if, for example, an outage happens in the filling machine. The alarm prevents the Filling Machine from producing packages if a homing is not completed.Conditions to set the alarmThe Sprue Remover unit has not performed a homing.Troubleshooting- Complete a homing on the Sprue Remover unit. To do a forced homing see Height Adjustment - Forced Homing.
- If a homing did not solve the problem do a Factory reset by following the steps below:
- Press Up button and down button simultaneously for 5 seconds to reset the height to the factory default value.
Note: When doing a factory reset of the height the recipe value saved for that top shape and volume will be reset to factory default value.
- Up button
- down button
Description
This chapter contains the maintenance procedures for the LFU. The functional description on page Functional Description provides a technical description of the LFU. Functional Description
The Lid Forming Unit (LFU) forms and fits a lid with an opening device at the top of the Tetra Top package. In the following pages, a short description is given of the path of the plastic through the LFU. The Colour Feed and the Transfer UnitIn the Colour feed, the Coloured granulate is fed into the Transparent PE granulate by a Cylinder. Depending on the lid design the programme controls the frequency for the valve. 
- Coloured granulate
- PE granulateTransparent
- Colour feed
- Cylinder
The quantity of plastic in the Accumulator is controlled by the speed of the Screw. The screw rotates continuously at high speed or at low speed. When the accumulator is empty, the screw moves at high speed. When the accumulator is half full with plastic, the screw moves at lower speed. The screw stops when the accumulator is full The transfer unit only operates when the machine is in running position. 
- Accumulator
- Screw
Hot Channel UnitThe plastic is transferred from the accumulator to the Injection cylinder through a heated Hose.There is a Non-return valve in the hot channel unit. When the injection cylinder is off, the plastic pressure returns to the cylinder piston. The stroke length of the injection cylinder can be adjusted by a Stop screw. The amount of plastic, called the dose, depends on the stroke length. The needle valve is kept closed by a Spring in a Pneumatic cylinder. When the injection starts the pneumatic is shut off and due to the plastic pressure the non-return valve is closed and the Needle is opened by the plastic pressure. 
A = CloseB = Open
- Hose
- Non-return valve
- Needle
- Injection cylinder
- Stop screw
- Spring
- Pneumatic cylinder
Identification of Hot Channel Piston VersionsThe main difference between the Hot Channel Pistons is the cooling body attached to the Pistons in version With Cooling. The different versions are illustrated in this Section.
Hot Channel Piston Version Without Cooling

Hot Channel Piston Version With Cooling
Piston unit (Valid for Hot Channel Version with Cooling)To reduce the plastic leakage, a unit with a Cylinder and a Piston is made with a specific gap, in the combination with a Cooling body results in a controlled plastic leakage. It’s possible to change the piston unit without changing the entire Hot Channel.
- Cylinder
- Piston
- Cooling body
Needle (Valid for Hot Channel Piston Version with Cooling)A needle unit with a Bushing and a Needle are matched to each other.
- Bushing
- Needle
Cooling circuit for Hot Channel Piston (Valid for Hot Channel Piston Version with Cooling)The cooling circuits purpose is to cool the plastic between the piston and the cylinder in order to not leak as liquid plastic. This is done with a water Cooling body on the cylinder and in a parallel a glycol circuit with a separate Flow meter. During stand still there is a pulse function that switches the water valve on and off to prevent plastic to freeze around the pistons.
- Flow meter
Movement of the External ToolsA servomotor and a hydraulic cylinder with two areas determine the movement of the external tools. The small area on the hydraulic cylinder is for the movement when the cylinder works together with the accumulator. The accumulator empties when the tools close and charges when the tools are open e.g. brake action. 
The illustration shows the small area

The illustration shows the big area
AccumulatorThe accumulator is a diaphragm membrane accumulator with an air connection on the non- hydraulic side. The air pressure is controlled by a regulator and a non-return valve. When the air pressure is below the set pressure, i.e., when the air volume is as big as possible, air is filled up through the regulator and the non-return valve. To avoid building up an over pressure on the accumulator’s oil side, the accumulator is bled through a small restrictor and a non-return valve. To make sure that there is correct pressure on the oil side, the accumulator is recharged once every cycle. This is done when the oil volume is maximum and is controlled by a directional valve. The recharging is done through a non-return valve and a pressure regulator. 
- Air Regulator
- Non Return Valve
- Air
- Accumulator
- Oil
- Bleeding
- Oil Pressure Regulator (recharging)
- Vertical Cylinder
- Directional Valve Recharging
LockDuring the closing of the tools, the pneumatically controlled Lock activates. The lock closes when it passes the Recess on the Horizontal force shaft. The sensor gives a signal and the hydraulically controlled Horizontal force cylinder activates to keep the halves of the external tools together. 
RearFrontThe illustration shows opened lock and opened external tools from above.

The illustration shows opened lock and closed external tools from the side.
- Lock
- Recess
- Horizontal force shaft
- Horizontal force cylinder

The illustration shows closed lock and closed external tools.
- Lock
- Recess
- Horizontal force shaft
- Horizontal force cylinder
Distance CylinderThe distance cylinder keeps the external tools and the hot channels apart at the opening and closing of the tools. TightnessThe big area of the vertical force cylinder activates at low pressure, about 9 bar, to tighten between the hot channel and the tools.InjectionThe injection cylinders activate and inject plastic into the cavity. There are sensors for full and empty cylinder. Pressing When the injection cylinder is empty the sensors activate pressing e.g. the big area and high pressure on the vertical cylinder. The pressure is controlled by a proportional valve.The plastic cools down and pressing is done. Tightness releases and the horizontal force cylinder releases. The lock opens and the external tools open. Reference CylindersThe reference cylinders open the cavity at the injection. The reference cylinders are activated when the first lids are produced at start up. During a safety stop the length of the cylinder can be set when the cylinder is in deactivated position.Identification of Tool/Mandrel/Lid
Note: The type/amount of identification may vary depending of the lid. Some have less than below described (short of room for engraving or plug).An example: 2:2 / 4 = Side 2:2, mandrel no 4.
- Supplier
- Year and week
- Running number
- Drawing number and version
- Identification number on top of the internal tool.
- Engraved plug

The arrows shows the machine direction and the mandrel wheel spin direction.
Sequences for the LFU
Starting Position
- Mandrels in starting position. External tools fully open.
- Bearing half
- Mandrel shaft
- Vertical bar and clamp system lifted by springs. Distance mandrel axis to bearing halves about 0.5 mm.

- Pneumatic cylinder for lock fully open to let bars pass freely.
- Hot channel kept lower than tools by hydraulic distance cylinder. Hot channel 0.2 to 0.3 mm lower than external tools.
External Tools Start Closing after 20 msActivating Distances after 75 ms 
- Servomotor pulls belts. Belts move tool holders.
- The vertical force cylinders support lifting with accumulator (low pressure).

- Pneumatic cylinder for lock activated. Distances sliding on stops.
External Tools Closed 
- Lock snapped in behind stops. Control sensor closed activate. If not, the machine stops. This starts:
- Horizontal force cylinder activated.
- Distance cylinders which keep external tools and hot channel down are released.
20 ms after External Tools Closing 
Check injection cylinder charged. If not, the machine stops.
- Vertical force cylinder shifted from accumulator to tightness pressure.
40 ms after External Tools Closing 
- Injection cylinder activated and deactivated (off) pneumatic cylinder for needle closing. Injection of plastic. The sensor signals "injection ready". If not, the machine stops.
After Signal Injection Ready 
- Pneumatic cylinder for lock activated to open.
- Cylinders in reference stop released. Activate pneumatic cylinder (on). This happens only in starting position.
- Vertical force cylinder shifted from tightness to pressing pressure.
950 ms after Starting Position 
- Vertical force cylinder shifted from pressing to tightness pressure.
After 990 ms after Starting Position 
- Vertical force cylinder shifted to accumulator.
1160 ms after Starting Position 
- Horizontal force cylinder released
- Lock snapped out.
- Signal from sensor lock open checked to be activated. If not, the machine stops. Distance cylinders which keep external tools and hot channel down are activated.
Signal Lock Open after 1350 ms 
- Servomotor starts to open external tools if the lock is open. This does not happen if signal from sensor lock open checked to be activated and the machine stops.
- Vertical force cylinders damping by accumulator (low) pressure.
Opening of External Tools after 1430 ms 
Recharging of accumulator activated.
End of Cycle after 1600 ms 
Recharging of accumulator activated.
LFU Cylinder SequencesThe following diagram shows the cylinder sequences during an LFU cycle. The valves shown in the illustration are from side 1. The cycle is identical for side 2.Note: The dashed time line shows a sequence prestart. The prestart time is set in the PLC. This is done to gain time for pressing and cooling.| No. | Valve | S1 | S2 |
| A | Locking cylinder valve | A30K1284 | A30K2284 |
| B | Tightness cylinder valve | A30K1226 | A30K2226 |
| C | Injection air cylinder needle valve | A30K1285 | A30K2285 |
| D | Horizontal cylinder valve | A30K1229 | A30K2229 |
| E | Reference stop cylinder valve | A30K1225 | A30K2225 |
| F | Distance cylinder valve | A30K1228 | A30K2228 |
| G | Logic element valve | A30K1224 | A30K2224 |
| H | Injection cylinder valve | A30K1227 | A30K2227 |
| I | Pressing cylinder valve | A30K1222 | A30K2222 |
| J | Recharging accumulator cylinder valve | A30K1223 | A30K2223 |
Hydraulic Vertical Force CylinderAlarms and Troubleshooting LFU
OverviewThe illustration shows an overview of all the alarms that can occur on the TPOP regarding the LFU.Alarm 110303331/11030332 “No Granulate”
DescriptionGranulate is used to make lids in the machine. It is transported into the LFU by the Granulate pipe. The Capacitive sensor checks if there is granulate in the Granulate pipe. The sensors are adjustable for both position and sensitivity.Conditions to set the alarmThe alarm will be set if the Capacitive sensor gives no signal.- Side 1 stops feeding in new packaging material.
- Side 1 continues production and uses up the remaining packaging material on that side of the machine.
- Side 1 steps down to MOTOR RUNNING.
- After 10 minutes, side 1 steps down to TANK FILLING.
- Side 2 stays in production.
- Side 2 stops feeding in new packaging material.
- Side 2 continues production and uses up the remaining packaging material on that side of the machine.
- Side 2 steps down to MOTOR RUNNING.
- After 10 minutes, side 2 steps down to TANK FILLING.
- Side 1 stays in production.

- Capacitive sensor
- Granulate pipe
Troubleshooting- Incorrect angle of the granulate pipes leading into the transfer unit. Check and adjust the hose and piping between the hopper and the metering device according to:
- Metering Device - Install
- Faulty or incorrectly set capacitive sensor on the granulate pipe leading into the transfer unit. Correct according to:
- Metering Device - Set
- Plastic residue is stuck in the pipe before the transfer unit, caused by an incorrect setting of the valves in the granulate container. Set according to:
- Installation Manual 4.6.3.4 Setting of the Granulate Velocity
Alarm 110303510/110303520/110703520/110703530 "Granulate Hopper MB/PE, Feeding Fault"
DescriptionThe granulate hopper receives granulate from the GSU and supplies the transfer unit in S1 and S2 with PE and MB.Conditions to set the alarmThe alarm will be set if the Proximity switch is active longer than the time set in the PLC. When the alarm 110303510/110303520/110703520/110703530 appears, both sides steps to PRODUCTION END. When the sides are empty the machine steps down to HEATING.
- Proximity switch
TroubleshootingAlarm 110303361/110303381/110303401/110303362/110303382/110303402 "Transfer Unit Too Long Heating Time"
DescriptionThe transfer unit transports the granulate from the granulate pipe to the plastic accumulator while melting and mixing the plastic. The transfer unit has heating elements to melt the plastic.Temperature sensors are placed in three zones on the transfer unit. The operating temperature of the transfer unit must be reached with the time set in the PLC.A signal is sent from the temperature sensors if the operating temperature is reached within the set time.This alarm can only occur within the first 30 minutes after the machine steps to program step HEATING. If the operating temperature is reached within the first 30 minutes after the machine steps to program step HEATING the alarm can not occur.Conditions to set the alarmThe alarm will be set if the operating temperature was not reached within the time set in PLC.- Side 1 stops feeding in new packaging material.
- Side 1 continues production and uses up the remaining packaging material on that side of the machine.
- Side 1 steps down to MOTOR RUNNING.
- After 10 minutes, side 1 steps down to TANK FILLING.
- Side 2 stays in production.
- Side 2 stops feeding in new packaging material.
- Side 2 continues production and uses up the remaining packaging material on that side of the machine.
- Side 2 steps down to MOTOR RUNNING.
- After 10 minutes, side 2 steps down to TANK FILLING.
- Side 1 stays in production.

- Zone 1 - S1 110303361, S2 110303362
- Zone 2 - S1 110303381, S2 110303382
- Zone 3 - S1 110313401, S2 110303402
Troubleshooting- Check that the temperature rises and falls back to the set value within 5 minutes in step HEATING.
- Defective heating element. Check according to: Transfer Unit - Check
- Check the measuring point connection to the measuring object.
- Check the fuses and the solid state relay according to:EM
Alarm 110303371/110303391/110303411/110303372/110303392/110303412 “Transfer Unit Wrong Temp”
DescriptionThe transfer unit transports the granulate from the granulate pipe to the plastic accumulator while mixing and melting the plastic. The transfer unit has heating elements to melt the plastic.Temperature sensors are placed in three zones on the transfer unit. The set temperature of the transfer unit must be within the alarm limits.Conditions to set the alarmThe alarm will be set if the set temperature value is outside of the alarm limits.- Side 1 stops feeding in new packaging material.
- Side 1 continues production and uses up the remaining packaging material on that side of the machine.
- Side 1 steps down to motor running.
- After 10 minutes, side 1 steps down to tank filling.
- Side 2 stays in production.
- Side 2 stops feeding in new packaging material.
- Side 2 continues production and uses up the remaining packaging material on that side of the machine.
- Side 2 steps down to motor running.
- After 10 minutes, side 2 steps down to tank filling.
- Side 1 stays in production.

- Zone 1 - S1 110303371, S2 110303372
- Zone 2 - S1 110303391, S2 110303392
- Zone 3 - S1 110303411, S2 110303412
TroubleshootingThe temperature is outside of the alarm limits set in the PLC. This alarm can also occur when the machine is in operating temperature and is stepped down below heating and then up to heating or higher. Alarm 110303561/110303562 “Accumulator Too Long Heating Time”
DescriptionThe plastic accumulator gathers the melted plastic from the transfer unit before the plastic reaches the hot channel.The plastic accumulator has heating elements to keep the plastic melted. The operating temperature of the accumulator must be reached within the time set in the PLC. A signal is sent from the temperature sensors if the temperature is reached within the set time.This alarm can only occur within the first 30 minutes after the machine steps to program step heating. If the operating temperature is reached within the first 30 minutes after the machine steps to program step heating the alarm can not occur.Conditions to set the alarmThe alarm will be set if the operating temperature is not reached within the time set in the PLC.- Side 1 stops feeding in new packaging material.
- Side 1 continues production and uses up the remaining packaging material on that side of the machine.
- Side 1 steps down to MOTOR RUNNING.
- After 10 minutes, side 1 steps down to TANK FILLING.
- Side 2 stays in production.
- Side 2 stops feeding in new packaging material.
- Side 2 continues production and uses up the remaining packaging material on that side of the machine.
- Side 2 steps down to MOTOR RUNNING.
- After 10 minutes, side 2 steps down to TANK FILLING.
- Side 1 stays in production.

- Plastic accumulator
Troubleshooting- Check that the temperature rises and falls back to the set value within 5 minutes in step HEATING.
- Defective heating element.Check according to:Transfer Unit - Check
Alarm 110303571/110303572 “Accumulator Wrong Temp”
DescriptionThe plastic accumulator gathers the melted plastic from the transfer unit before the plastic reaches the hot channel. The plastic accumulator has heating elements to keep the plastic melted. The setting temperature of the plastic accumulator must be within the alarm limits.Conditions to set the alarmThe alarm will be set if the setting temperature value is outside of the alarm limits.- Side 1 stops feeding in new packaging material.
- Side 1 continues production and uses up the remaining packaging material on that side of the machine.
- Side 1 steps down to MOTOR RUNNING.
- After 10 minutes, side 1 steps down to TANK FILLING.
- Side 2 stays in production.
- Side 2 stops feeding in new packaging material.
- Side 2 continues production and uses up the remaining packaging material on that side of the machine.
- Side 2 steps down to MOTOR RUNNING.
- After 10 minutes, side 2 steps down to TANK FILLING.
- Side 1 stays in production.

- Plastic accumulator
Troubleshooting- The temperature is outside of the alarm limits set in the PLC. This alarm can also occur when the machine is in operating temperature and is stepped down below heating and then up to heating or higher. Step up to heating and wait 5 minutes. Check the temperature windows to see if the levels return to the set limits according to:Transfer Unit - Check
Alarm 110303581/110303601/110303582/110303602 “Hose Too Long Heating Time”
DescriptionA heated hose transfer the melted plastic from the plastic accumulator to the hot channel. The heated hose have heating elements to keep the plastic melted during the transfer. The operating temperature of the heated hose must be reached within the set time in the PLC. A signal is sent from the temperature sensors if the operating temperature is reached within the set time. This alarm can only occur within the first 30 minutes after the machine steps to program step heating. If the operating temperature is reached within the first 30 minutes after the machine steps to program step heating the alarm can not occur.Conditions to set the alarmThe alarm will be set if the operating temperature was not reached within the time set in the PLC.- Side 1 stops feeding in new packaging material.
- Side 1 continues production and uses up the remaining packaging material on that side of the machine.
- Side 1 steps down to MOTOR RUNNING.
- After 10 minutes, side 1 steps down to TANK FILLING.
- Side 2 stays in production.
- Side 2 stops feeding in new packaging material.
- Side 2 continues production and uses up the remaining packaging material on that side of the machine.
- Side 2 steps down to MOTOR RUNNING.
- After 10 minutes, side 2 steps down to TANK FILLING.
- Side 1 stays in production.

- Heated hose S1 1:1 110303581 / S2 2:1 110303601
- Heated hose S1 1:2 110303582 / S2 2:2 110303602
TroubleshootingAlarm 110303591/110303611/110303592/110303612 “Hose Wrong Temp”
DescriptionA heated hose transfer the melted plastic from the plastic accumulator to the hot channel. The heated hose has heating elements to keep the plastic melted during the transfer. The set temperature of the heated hose must be within the alarm limits.Conditions to set the alarmThe alarm will be set if the set temperature value is outside of the alarm limits.- Side 1 stops feeding in new packaging material.
- Side 1 continues production and uses up the remaining packaging material on that side of the machine.
- Side 1 steps down to MOTOR RUNNING.
- After 10 minutes, side 1 steps down to TANK FILLING.
- Side 2 stays in production.
- Side 2 stops feeding in new packaging material.
- Side 2 continues production and uses up the remaining packaging material on that side of the machine.
- Side 2 steps down to MOTOR RUNNING.
- After 10 minutes, side 2 steps down to TANK FILLING.
- Side 1 stays in production.

- Heated hose S1 1:1 110303591 / S2 2:1 110303611
- Heated hose S1 1:2 110303592 / S2 2:2 110303612
Troubleshooting- The temperature is outside of the alarm limits set in the PLC. This alarm can also occur when the machine is in operating temperature and is stepped down below heating and then up to heating or higher. Step up to heating and wait 5 minutes. Check the temperature windows to see if the levels return to the set limits according to:Transfer Unit - Check
Alarm 110303421/110303441/110303422/110303441 “Hot Channel Too Long Heating Time”
DescriptionThe hot channel is where the melted plastic is injected into the initial cavity. The hot channel has heating elements to keep the plastic melted during the injection. The operating temperature of the hot channel must be reached within the time set in the PLC. A signal is sent from the temperature sensors if the operating temperature is reached within the set time. This alarm can only occur within the first 30 minutes after the machine steps to program step heating. If the operating temperature is reached within the first 30 minutes after the machine steps to program step heating the alarm can not occur.Conditions to set the alarmThe alarm will be set if the operating temperature was not reached within the set time in the PLC.- Side 1 stops feeding in new packaging material.
- Side 1 continues production and uses up the remaining packaging material on that side of the machine.
- Side 1 steps down to MOTOR RUNNING.
- After 10 minutes, side 1 steps down to TANK FILLING.
- Side 2 stays in production.
- Side 2 stops feeding in new packaging material.
- Side 2 continues production and uses up the remaining packaging material on that side of the machine.
- Side 2 steps down to MOTOR RUNNING.
- After 10 minutes, side 2 steps down to TANK FILLING.
- Side 1 stays in production.

- Hot channel S1 1:1 30342 / S2 2:1 31342
- Hot channel S1 1:2 30344 / S2 2:2 31344
TroubleshootingAlarm 110303431/110303451/110303432/110303452 “Hot Channel Wrong Temp”
DescriptionThe hot channel is where the melted plastic is injected into the initial cavity. The hot channel has heating elements to keep the plastic melted during the injection. The set temperature of the hot channel must be within the alarm limits.Conditions to set the alarmThe alarm will be set if set temperature value is outside of the alarm limits.- Side 1 stops feeding in new packaging material.
- Side 1 continues production and uses up the remaining packaging material on that side of the machine.
- Side 1 steps down to MOTOR RUNNING.
- After 10 minutes, side 1 steps down to TANK FILLING.
- Side 2 stays in production.
- Side 2 stops feeding in new packaging material.
- Side 2 continues production and uses up the remaining packaging material on that side of the machine.
- Side 2 steps down to MOTOR RUNNING.
- After 10 minutes, side 2 steps down to TANK FILLING.
- Side 1 stays in production.

- Hot channel S1 1:1 110303431 / S2 2:1 110303432
- Hot channel S1 1:2 110303451 / S2 2:2 110303452
Troubleshooting- The temperature is outside of the alarm limits set in the PLC. This alarm can also occur when the machine is in operating temperature and is stepped down below heating and then up to heating or higher. Step up to heating and wait 5 minutes. Check the temperature windows to see if the levels return to the set limits according to:Transfer Unit - Check.
Alarm 110303461/110303462 “Tools Not Completely Opened”
DescriptionThe servomotor starts to open the external tools when the injection and pressing is complete and the horizontal lock is open. The oil in the vertical cylinder is forced back into the accumulator. When the external tools are completely open the vertical force cylinder is in its bottom position and the Proximity switch activates.Conditions to set the alarmThe alarm will be set if the tools are not opened within the sector value range 1550 - 1590.When this alarm appears the machine performs a quick stop and steps down to heating.
- Proximity switch
Troubleshooting- Slow or no response from the directional valve S1/A30K1228, S2/A30K2228. Check with logger and change valve S1/A30K1228, S2/A30K2228 according to:Directional Valve - Change
- Faulty feedback cable. Change the cable temporarily and test.
- The gear box is slipping. Check according to:Motor Unit - Check BeltMotor Unit - Overhaul
- Air in horizontal cylinder Perform a bleeding according to:Hydraulic System LFU - BleedIf bleeding is required frequently, the reason can be air leakage through an invisible hole in the cylinder hydraulic hose. Check or change the affected hydraulic hose and perform a new bleeding.
Alarm 110303471/110303472 “Tools Not Closed, Injection Cycle Interrupted”
DescriptionThe servomotor pulls the belts that close the external tools. When the external tools are completely closed and locked, the Proximity switch is activated.Conditions to set the alarmThe alarm will be set if the tools are not closed within the sector value range 230 - 300.When this alarm appears the machine performs a quick stop and steps down to heating.
- Proximity switch
TroubleshootingAlarm 110303481/110303491/110303482/110303492 "Injection Cylinder Not Filled"
DescriptionTo perform an injection, the hot channel must have a full dosage of plastic within the sector value range 220-270.When the hot channel is filled the front Inductive switch is activated and the injection begins.Conditions to set the alarmThe alarm will be set if there is no signal from the front Inductive switch to the PLC within the sector value range 220-270.When this alarm appears the machine performs a Controlled Quick Stop and steps down to program step heating.
- Inductive switch
TroubleshootingAlarm 110303621/110303631/110303622/110303632 "Too Long Injection Time, Injection Not Completed"
DescriptionThe Inductive switch is active when the injection cycle is completed and the injection cylinder is empty of plastic. The injection cycle begins at the sector value range 340 - 390.Conditions to set the alarmThe alarm will be set if the injection is not complete within the selected sector value range, see table.| Base | 630-730 |
| Midi | 600-700 |
| Mini | 600-700 |
| Micro | 600-700 |
When this alarm appears the machine performs a Controlled Quick Stop and steps down to program step heating.
- Inductive switch
Waste 110035041/110035042 - Waste in LFUThe first pair of packages after an empty carton section is aborted empty, if the time for injection is passing the limits for the alarm of “Too long injection time, injection not completed” to avoid stopping the machine. If the injection time during the first shot is passing sector 800 it will give a yellow alarm for “Too long injection time, injection not completed”.TroubleshootingAlarm 110303501/110303502 "Mandrel Wheel Error"
DescriptionEach mandrel wheel is driven by a Servomotor through a planetary gear. The servomotor works as overload protection and controls the mandrel wheel indexing movement.Conditions to set the alarmThe alarm occurs due to a position fault or resolver function error. The position fault can be due to overload or interrupted movement.When this alarm appears the machine performs a quick stop and steps down to heating.
- Servomotor
TroubleshootingAlarm 110303641/110303642 “Feeder Motor Overload”
DescriptionThe feeder motor drives the transfer unit screw at different speeds. The speed is controlled by the level switches on the accumulator. A low level gives high speed. If high speed is on for more than 30 seconds the motor stops to avoid plastic leakage and to avoid that any part in the system breaks.Conditions to set the alarmThe alarm will be set if the plastic accumulator Inductive switch has been active for more than 30 seconds in the steps motor running, Production or Production End.
- Inductive switch
Troubleshooting- The transfer unit screw has run more than 30 seconds at high speed. Check that there is granulate coming into the transfer unit.
- Plastic stuck in the inlet to the transfer unit. Clean according to:- OM
- Faulty accumulator location transmitter (position or function). Check according to:Transfer Unit - Set Frequency
- Leaking system, most likely a heating hose. Repair the leak.
- Incorrectly set frequency converter. Check according to:Transfer Unit - Set Frequency
Alarm 110303661/110303662 “Hydraulic Accumulator Wrong Pressure”
DescriptionThe hydraulic accumulator supports the servomotor in the tool movement. The air pressure in the accumulator is recharged over a non-return valve by pneumatic air to 2.8-3.0bar and then by hydraulic oil, recharged to 13bar. The accumulator air pressure varies during the cycle due to the volume change of oil in the accumulator, open or closed tools. In the cycle, when tools are opened, the recharge valve opens for a short time to obtain the pressure balance between the pneumatic air and the hydraulic oil in the accumulator. This is to compensate the bleeding. Bleeding is always on to avoid overfilling of oil due to the position change of the logic element. To detect a hydraulic overload by oil volume, the hydraulic pressure is supervised by the Pressure switch. With the tools closed, the accumulator unit is almost empty of oil. The hydraulic pressure is then normally 2-3bar.Conditions to Set the AlarmThe alarm will be set if there is a higher hydraulic pressure than 8bar in the accumulation unit during pressing at the sector value 500-1000. The normal value is 2 bar to 3bar.When this alarm appears, the machine performs an Empty Package Stop and steps down to Heating.
- Pressure switch
TroubleshootingAlarm (blue) 110303691/110303692 “High Torque/Position Error”
DescriptionThe Servomotor handles the opening and closing of the external tools together with the vertical force cylinder.The Servomotor drives a Belt that is connected to a Shaft. The Shaft has Toothed pulley where the Timing belt are attached.
- Servomotor
- Belt
- Shaft
- Toothed pulley
- Timing belt
Conditions to set the alarmThe blue alarm will be set if the torque is high or if the servomotor position is faulty. The alarm will only be set between sector values 1-200 and 1350-1530. The blue alarm will be set if the position fault is 0.050 or more. The alarm will also be set if the position fault is 0.025 or more during the homing sequence. TroubleshootingAlarm 110303701/110303702 “High Torque/Position Error”
DescriptionThe Servomotor handles the opening and closing of the external tools together with the vertical force cylinder.The Servomotor drives a Belt that is connected to a Shaft. The Shaft has Toothed pulley where the Timing belt are attached.
- Servomotor
- Belt
- Shaft
- Toothed pulley
- Timing belt
Conditions to set the alarmThe alarm will be set if the torque is high or if the servomotor position is faulty. The alarm will only be set between master positions 1-200 and 1350-1530. The alarm will be set if the position fault is 0.070 or more. The alarm will also be set if the position fault is 0.035 or more during the homing sequence. TroubleshootingAlarm 110303341/110303342 "Tool Movement Error"
DescriptionThe Servomotor handles the opening and closing of the external tools together with the vertical force cylinder. During the opening cycle the oil in the vertical cylinder is forced back into the accumulator. During the closing cycle the oil in the accumulator is forced back to the vertical cylinder by the air pressure in the top of the accumulator.Conditions to set the alarmThe alarm will be set if a position fault is detected due to overload/obstruction or feedback error.When this alarm appear the motors stop immediately and the machine steps to pre-heating.
- Servomotor
Troubleshooting- Bad grounding of the servomotor Check the condition and connections of the external grounding braids.Motor Unit - Change
- Internal error in servo drive. Check error code on servo drive according to:Servo System - General Troubleshoot
- The scissor movement is too slow. Check valve S1/A30K1223, S2/A30K2223 according to:Pressing Unit - Check Spacer and CylinderDirectional Valve - Change (Valid for A30K1223, A30K2223, A30K1225, A30K2225, A30K1228, A30K2228, A30K1229, A30K2229, A30K1226, A30K2226, A30K1222, and A30K2222) (2000)
- Incorrect accumulator pressure. Check according to:Accumulator Unit - Check Pressure
- Clogged flow restrictor. Check according to:Flow Restrictor - Check
- Long response time of the logic valve. Change valve S1/A30K1224, S2/A30K2224 according toDirectional Valve - Change (Valid for A30K1224, A30K2224, A30K1227 and A30K2227) (2000)
- Incorrectly centred timing belt. Check and adjust according to:Drive Tool - Set Belt Tension
- Faulty feedback cable. Change the cable temporarily and test.
- The gearbox has seized. Check according to:Motor Unit - Overhaul
LFU - Troubleshooting
Defective Lids - Causes and Actions
A. Leaking Corner
B. Difference in Lid Thickness between 1:1 and 1:2, or 2:1 and 2:2
C. Difference in Lid Thickness between Front and Back of the Same Lid
| Fault No | Fault | Proposed action | See MM Procedure: |
| C1 | There is a difference in lid thickness between front and back of the same lid. | Centre holder against reference stop. | LFU - Basic Set |
D. Opening Force Is Too High
| Fault No | Fault | Proposed action | See MM Procedure: |
| D1 | Lids are too thick. | Check the lid thickness. If they are too thick, decrease dosing and check for leaking corners and opening force. | Hot Channel - Basic Set of Plastic DosingTools - Check Lid |
| D2 | Damaged knife edge. | Check the edges on the knives for wear. | --- |
E. Sucked-In or Deformed Lids
| Fault No | Fault | Proposed action | See MM Procedure: |
| E1 | Lid-blowing does not work correctly. | Check the function of the lid-blowing.Check for clogged filters, MSPs, rubber sealing/washer for the on/off device, air pressure, and so on. | --- |
| E2 | Pressing is missing. | Check signal for the pressing cylinder valve (S1/A30K1222, S2/A30K2222). | LFU - Basic Set |
F. The Crease on the Sleeve Is Damaged under the Lid (Leaking Packages)
G. The Lid Bursts at the Pouring Edge and/or Broken Pull-Ring (Mainly at Start Up)
H. Plastic Leakage on the Hot Channel (Flash on the Pull-Ring)
I. Injection Cycle Interrupted (No Lid(s))
| Fault No | Fault | Proposed action | See MM Procedure: |
| I1 | Broken spring in the vertical cylinder. | Check the spring in the vertical cylinder that holds the piston rod toward the hot channel. | --- |
| I2 | Function of the needles in the hot channels is incorrect. | Broken or stuck needles.Check the movement of the needles. | Hot Channel - Set Needle |
| I3 | Empty injection cylinders. | Check that granulate is fed into the dosing unit.Check the transfer unit motor.Check the plastic accumulator.Clogged transfer unit:- Lift the dosing unit and remove pieces of granulate.
- Remove the screw and clean it.
Condense water in the transfer unit. Adjust the ice water flow to the transfer unit.Check the needles. | Hot Channel - Set Needle |
| I4 | Function of the lifter plate is incorrect. | Check for correct abortion of the first blank. | --- |
| I5 | Function of the injection valve, or the nozzle valve is incorrect. | Check the valves. | --- |
J. Ready for Injection Takes Too Long
| Fault No | Fault | Proposed action | See MM Procedure: |
| J1 | The transfer unit motor does not work correctly. | Check the motor. | --- |
| J2 | The injection cylinder does not work correctly. | Check and adjust if necessary. | --- |
| J3 | The accumulator settings are wrong. | Check and adjust if necessary. | --- |
| J4 | Wrong accumulator pressure. | Check and adjust if necessary. | --- |
| J5 | The temperature on the plastic hoses from the accumulator to the transfer unit. | Check and change if necessary. | --- |
| J6 | Plastic leakage in the plastic hoses. | Check the plastic hoses. | --- |
K. Injection Takes Too Long
L. Damaged Underside of the External Tools
| Fault No | Fault | Proposed action | See MM Procedure: |
| L1 | Wrong hot channel setting. | Check/set the 0.6-mm gap between the external tools and the hot channel. | LFU - Basic Set |
M. Incomplete Lid(s)
| Fault No | Fault | Proposed action | See MM Procedure: |
| M1 | Plastic leakage between the hot channel and the external tools. | Check, and if necessary, clean between the external tools and the hot channel. | Hot Channel - Set Needle |
| M2 | No pressing. | Check the pressing pressure.Check the reference cylinder. | LFU - Basic Set |
| M3 | Plastic dosing too low. | Measure the lid. If the lid is thinner than x, increase the plastic dosing. | Hot Channel - Basic Set of Plastic Dosing |
| M4 | Pressure too low. | Increase the pressure and see if this action solves the problem. | Pressing Pressure - Set |
N. Plastic Leakage from Hot Channel Piston
O. Overmoulding/Flashing Tools
Valid for: Tools with spring-loaded bushingPE drop at LS inside of a Tetra Top package
Important information about the PE drop at the LS
Background
The PE drop at LS (plastic flash) that can be seen inside the package is a natural part of the Tetra Top package design. The drop is caused by tolerances and safety precautions that are set so that the packaging material is not punctured when double material gets squeezed between the outer and inner tools.The input for the safety margins (LS compensation in tool) is:- The tolerance of the material web reel
- The sleeve tolerance when sealing
- The sleeve rotation when putting the sleeve into position for lid forming
The tools are designed to compensate for all the tolerances and ensure that the packaging material is not punctured.Due to the fact that LS overlap will vary from reel to reel the LS clearance for the tool has to be large enough for the largest LS without puncturing the sleeve. The PE drop is caused when the LS width on the sleeve is smaller than the LS clearance. Size of the PE drop
Because of the huge variety of the different top designs and sizes it is impossible to say what size and appearance the PE drop must have. As long as the machine can strip the package from the mandrels the PE drop is small enough. The PE drop is needed to produce safe packages with maintained package integrity. As long as the packages pass the destructive and blue ink package integrity checks according to OM – Package Check, the PE drop is large enough.Factors that influence the PE drop size
Lid Thickness
The lid thickness depends on the plastic dosing and pressing pressure. Increasing the plastic dosing without changing the pressing pressure will result in a thicker lid. Decreasing the plastic dosing without changing the pressing pressure it will result in a thinner lid.The plastic dosing together with the pressing pressure also affects the shape and size of the PE drop.By increasing or decreasing the plastic dosing and at the same time increasing or decreasing the pressing pressure the shape and size of the PE drop and the lid thickness will change. Note: Going outside of the specified limits of lid thickness will create problems with integrity, capping, heat and stability.Package material
The width of the reel can differ from reel to reel, while staying within the tolerance of the packaging material. This makes the LS overlap slightly larger or smaller. A smaller LS overlap creates a bigger PE drop.Pressing pressure on LFU
The pressing pressure is used to press the plastic into the moulding tool cavity. A higher pressing pressure can make the PE drop larger, and a lower pressure can make it smaller. The values in the MM are default values and can be adjusted in order to optimise the performance. Approximately a ±10% change can be used if all other settings are OK and the package functionality is OK.Note: The pressing pressure will directly affect the lid thickness. A smaller pressing pressure will make the lid thicker but also increase the risk of the plastic does not cover the sleeve completely or holes in the lid.Sleeve top circumference
The sleeve top circumference affects the LS overlap which then affects the plastic flash. A smaller sleeve top circumference causes a bigger LS overlap and a smaller PE drop.Note: An incorrect sleeve size will seriously affect the package integrity and performance of the machine. Mechanical setting of LFU and tools
Incorrect mechanical settings can influence the PE drop in both directions. LFU and tools must be set according to the MM.Factors that influence the PE drop position
Crease position
The crease position set by the operator directly affects the position of the PE drop. If the crease is moved to the left in the ASU the PE drop will move to the left side of the LS as seen from the inside of the package.Note: The positioning of the crease is something the operator check and change often due to the factory creasing position on the package material. There is only one setting for this and that is in the centre of the K crease in the bottom of the package. If this is out of position it will affect the bottom and flap sealing of the package.Sleeve rotation on the mandrel
The sleeve rotation on the mandrel will affect the position of the PE drop. There is only one setting for this and that is that the crease on the sleeve must be aligned with the centre of the outer moulding tools.Note: If the sleeve position on the mandrel is incorrect, a basic setting of the erector unit is needed.LFU - Set Basic Alignment
| Equipment Status | Program Step |
| Special Equipment | Ruler, TP No. 2678694 Template vertical guide, TP No. 2787510 Deep Gauge, TP No. 2760316 or Deep Gauge, TP No. 3424768 |
Risk of injuryBe careful when working near the shims.The shims in the LFU could be sharp.
Risk of crushingBe careful when working near the moving parts. It is recommended to use trained personnel when working with the LFU unit in service position. Enclose the area around the LFU and make sure that no unauthorized personnel can come in contact with the LFU.The machine contains moving parts that can crush.
Preparation
- Roll out the LFU, see Procedure LFU - Move to Service Position.The rulers must be assembled on the docking side of the LFU. All illustrations show the docking side of the LFU on S1.
- Remove the Mandrel wheel, see Procedure Mandrel Wheel - Remove.
- Fit the Ruler spacer on the lower side and the Ruler.

LFU docking side
- Mandrel wheel
- Ruler spacer
- Ruler
- Remove the Bearing Half, including the Washer and the Shim.Note: Notice on which side the Shim are situated, do not mix between the sides.
- Loosen the four Screw, so that the Guide is floating free.
- Loosen the Screw, so that the Guide is floating free.
- Loosen the Counter nut and screw and the Screw.

- Bearing Half
- Washer
- Shim
- Screw
- Guide
- Screw
- Guide
- Counter nut and screw
- Screw
- Assemble the Template (2787508). Make sure that the Template (2787508) is aligned by the Guide pin and the Guide pin.Note: Assemble the Template (2787508) so that the Guide pin is put in the round template hole on the docking side, and the Guide pin in the oval template hole.
- Assemble the Ring (2799356, 2 pc and 2799357, 4 pc) in the Template (2787508).

- Template (2787508)
- Guide pin
- Guide pin
- Ring (2799356, 2 pc and 2799357, 4 pc)
- Adjust the middle bars:
- Slightly push the middle bars to make the rings fall down.Note: Do not tighten any screws.
- Adjust the outer bars:
- Slightly push the Guide to make the rings fall down.Note: Do not tighten any screws.

- Guide
Positioning
In the front of and the side of the frame (see arrows in illustration) there are engraved figures. The figures come from a check of the frame against the drawing specification.A deviation from the nominal measure at each measuring point, results in an engraved figure in the frame. If the measuring spot is on the nominal value, the engraving is 0.When to useTo set the vertical guide to a correct position, the bars must be set to the nominal value against the measuring surfaces. The value that is measured must be compensated with the marked deviation when setting the vertical guide. The engraved marking is the deviation from ±0 and is a factory set value. 
- Measure the distances A, B, C, and D with a Deep gauge.Engraved values on the frame can be specified in two different ways, for example: -16 or -0.16: Both values mean -0.16 mm.Negative engraved values mean the surface on the frame is below nominal value. Positive engraved values mean the surface on the frame is above nominal value.
- Compensation: Measured setting value should be compensated with the engraved value.
- Example no. 1: Engraved -0.16 must be added as 0.16 to the measured value.
- Example no. 2: Engraved 0.10 must reduce the measured value by 0.10.

Views from above
- Deep gauge
- Ruler
Note: Use the template in Section to fill in the measured values.- Measure B upper. Add or reduce the engraved value.
- Measure B lower. Add or reduce the engraved value.
- The difference between the compensated values B upper and B lower should be within tolerance ±0.05, to make mechanism vertical.
- Measure A lower. Add or reduce the engraved value.
- Measure C lower. Add or reduce the engraved value.
- The difference between the compensated values A lower and C lower should be within tolerance ±0.05, to make mechanism parallel to the mandrel shaft.
- Measure D front upper. Add or reduce the engraved value.
- Measure D front lower. Add or reduce the engraved value.
- The difference between the compensated values D front upper and D front lower should be within tolerance ±0.05, to make mechanism vertical.
- Example of first measurement
| Engraved value | A | B | C | D (front) |
| Upper | 9 | 11 | 18 | 0 |
| Lower | 10 | 11 | 12 | -16 |
| A upper | B upper | C upper | D (front) upper |
| Engraved value | N/A | 11 | N/A | 0 |
| Compensation | N/A | -0.11 | N/A | 0.00 |
| Measured | N/A | 252.22 | N/A | 135.40 |
| Compensated | N/A | 252.11 | N/A | 135.40 |
| A lower | B lower | C lower | D (front) lower |
| Engraved value | 10 | 11 | 12 | -16 |
| Compensation | -0.10 | -0.11 | -0.12 | 0.16 |
| Measured | 257.32 | 252.24 | 257.25 | 135.31 |
| Compensated | 257.22 | 252.13 | 257.13 | 135.47 |
Example of first measurement calculationCompensated B upper - Compensated B lower = Result| Compensated B upper | Compensated B lower | Result | Tolerance | Pass/Fail |
| 252.11 | 252.13 | -0.02 | ±0.05 | Pass |
Compensated A lower - Compensated C lower = Result| Compensated A lower | Compensated C lower | Result | Tolerance | Pass/Fail |
| 257.22 | 257.13 | 0.09 | ±0.05 | Fail |
Compensated D upper - Compensated D lower = Result| Compensated D upper | Compensated D lower | Result | Tolerance | Pass/Fail |
| 135.40 | 135.47 | -0.07 | ±0.05 | Fail |
- If adjusting is necessary, loosen the four Nut.
- Move the vertical guide Attachment point, in chosen direction, by adjusting the Screw, at each attachment point to reach position within tolerances.Note: Loosen the opposite adjusting Screw before the adjusting (to prevent tensions). Tighten the Screw after the adjustment is done.
- Tighten the Nut.
- Also tighten the Screw slightly.
- Measure the distances A, B, C, and D again to ensure that the set distances are within tolerances.

- Nut
- Attachment point
- Screw
- Screw
- Example of measurement after adjustment
| A upper | B upper | C upper | D (front) upper |
| Engraved value | N/A | 11 | N/A | 0 |
| Compensation | N/A | -0.11 | N/A | 0.00 |
| Measured | N/A | 252.19 | N/A | 135.44 |
| Compensated | N/A | 252.08 | N/A | 135.44 |
| A lower | B lower | C lower | D (front) lower |
| Engraved value | 10 | 11 | 12 | -16 |
| Compensation | -0.10 | -0.11 | -0.12 | 0.16 |
| Measured | 257.26 | 252.24 | 257.25 | 135.31 |
| Compensated | 257.16 | 252.13 | 257.13 | 135.47 |
Example of calculation after adjustmentCompensated B upper - Compensated B lower = Result| Compensated B upper | Compensated B lower | Result | Tolerance | Pass/Fail |
| 252.08 | 252.13 | -0.05 | ±0.05 | Pass |
Compensated A lower - Compensated C lower = Result| Compensated A lower | Compensated C lower | Result | Tolerance | Pass/Fail |
| 257.16 | 257.13 | 0.03 | ±0.05 | Pass |
Compensated D upper - Compensated D lower = Result| Compensated D upper | Compensated D lower | Result | Tolerance | Pass/Fail |
| 135.44 | 135.47 | -0.03 | ±0.05 | Pass |
Assembly
- Remove the rulers with brackets.
- At this point the rings should be sliding easily down, when lifted, without any force added in any direction.
- Tighten the Screw and the Screw with the correct torque.
- At this point the rings should be sliding easily down, when lifted, without any force added in any direction.
- Remove the template.

- Screw
- Screw
- Fit the Bearing Half, the Shim, the Steel washer, and the Bronze washer.Note: Notice on which side the Shim are situated, do not mix between the sides. Change all damaged Shim.Note: Place the thickest Shim on top and the thinnest Shim in the middle.

- Bearing Half
- Shim
- Steel washer
- Bronze washer
- Assemble the mandrel wheel, see Procedure Mandrel Wheel - Assemble.
- Set the tools, see Procedure External Tools - Set Centre of Tools.
- If no basic set is performed or registrated, perform a basic set. See Procedure LFU - Basic Set.
- Set the support to reference stop, see Procedure LFU - Set Support to Reference Stop.
- Install the LFU, see Procedure LFU - Install from Service Position.
LFU - Basic Set
Included in the TT/3 MM and UP for Conv. Kit Openings | Equipment Status | Program Step HEATING |
| Special Equipment | Protective goggles TP No. 90303-0011 Protective gloves TP No. 90303-0012 Tin Solder ø 1.5 mm Tin Solder ø 1 mm Measuring tool, TP No. 2787511-0100 Template, TP No. 2799379-0000 Fork spanner 41 mm Fork spanner 46 mm Rubber club Micrometre Feeler gauge Hex key 5 mm Crowbar Template Template Template Template Template Template Template Template |
| Consumables | Antiseize, TP No. 344417-0000 |
[1] Template for opening C38 with spring-loaded bushing.Risk of injuryBe careful when working near the shims.The shims in the LFU could be sharp.
Oil under pressure.Use protective goggles when working near and around the
LFU unit. Check the condition of the hydraulic hoses and connections before setting the machine into service mode. If necessary, change the hoses. See Procedure
Hydraulic System LFU - Change Hydraulic Hoses.Risk of eye injury.
Risk of crushing.Be careful when working near the moving parts. Use trained personnel when working with the LFU unit in service position.The machine contains moving parts that can crush.
Foreword
It is important that the LFU is in range for its working temperature (heating) during the whole performance of the basic setting. Otherwise, the performed checks and settings are not reliable.Note: Before a decision is taken to perform the basic setting, check the pressures according to the list:- BleedIf the LFU hydraulic system has been opened, bleed. See Procedure Hydraulic System LFU - Bleed.
- Accumulator Air PressureCheck and if necessary, set the accumulator air pressure. See Procedure Pneumatic Pressures LFU - Set.
- Accumulator Hydraulic PressureCheck and if necessary, set the accumulator hydraulic pressure. See Procedure Hydraulic Accumulator Pressure - Set.
- Injection Cylinders and Horizontal Cylinders
The Basic Set Procedure-Sections
Move the LFU to Service Position
Remove the LFU. See Procedure LFU - Move to Service Position.Check the Tightness Pressure
- Make sure that the machine is in heating.
- Turn a mandrel pair (with sleeves) downwards.
- Measure the tightness pressure 1.8 MPa (18 bar) with a pressure gauge in the Measuring point vertical cylinder.
- Use the remote control. See Procedure LFU Remote Control - Handle. When the LFU is in working temperature, start:
- Step 1 Hydraulic High Pressure
- Step 2 Locking Scissors
- Close tools manually with the recharging valve on the hydraulic block.
- Step 3 Horizontal Force
- Step 4 Reference Cylinder
- Step 5 Tightness
- If necessary, adjust the tightness pressure on the Tightness reduction valve.
- Deactivate in the reverse order.

- Tightness reduction valve
- Measuring point vertical cylinder
Check Pressing Pressure
- Make sure that the machine is in heating.
- Turn a mandrel pair (with sleeves) downwards.
- Measure the pressing pressure with a pressure gauge in the Measuring point vertical cylinder.Note: The pressing pressure for the current opening is found in Procedure .
- Use the remote control. See Procedure LFU Remote Control - Handle. When the LFU is in working temperature, start:
- Step 1 Hydraulic High Pressure
- Step 2 Locking Scissors
- Close tools manually with the recharging valve on the hydraulic block.
- Step 3 Horizontal Force
- Step 4 Reference Cylinder
- Step 5 Tightness
- Step 6 Pressing
- If necessary, adjust the Adjusting Pressing Pressure.
- Deactivate in the reverse order.

- Adjusting Pressing Pressure
- Measuring point vertical cylinder
Check the Gap between Bearing Halves and Mandrel Shaft
Oil under pressureUse protective goggles when working near and around the
LFU unit. Check the condition of the hydraulic hoses and connections before setting the machine into service mode. If necessary, change the hoses. See
Hydraulic System LFU - Change Hydraulic Hoses.Risk of eye injury.
Risk of crushingBe careful when working near the moving parts. Use trained personnel when working with the LFU unit in service position.The machine contains moving parts that can crush.
- Remove the Screw and the Bracket. Use a 19-mm spanner to remove the Pin.
- Assemble the Beam on the Mandrel wheel.

- Screw
- Bracket
- Pin
- Beam
- Mandrel wheel
- Put the Dial Indicator, Dial Indicator, and Dial Indicator on the bearing halves Outer Bearing half, Middle Bearing Half, and Outer Bearing half.
- Turn on the service key.
- Use the remote control. See Procedure LFU Remote Control - Handle. Start:
- Step 1 Hydraulic High Pressure
- Step 2 Locking Scissors
- Close tools manually with the recharging valve on the hydraulic block.
- Step 3 Horizontal Force
- Step 4 Reference Cylinder
- Step 5 Tightness
- Set the Dial Indicator, Dial Indicator, and Dial Indicator to zero.
- Change between activate and deactivate for the tightness. Watch the Dial Indicator, Dial Indicator, and Dial Indicator.
- The indicated dial value on the bearing halves Outer Bearing half, Middle Bearing Half, and Outer Bearing half must be 0.2.

- Dial Indicator
- Dial Indicator
- Dial Indicator
- Outer Bearing half
- Middle Bearing Half
- Outer Bearing half
- If all three values are within range, continue to item Reference.
- Go to: Step 1 Hydraulic High Pressure, and set it to OFF.
- Deactivate the service key.
- Remove the Dial Indicator, Dial Indicator, and Dial Indicator.
- Remove the Beam.
- Assemble the Pin, the Bracket, and the Screw.

- Screw
- Bracket
- Pin
- Beam
- Mandrel wheel
- Dial Indicator
- Dial Indicator
- Dial Indicator
- Outer Bearing half
- Middle Bearing Half
- Outer Bearing half
Adjust the Height of the Middle Bearing Half
- Make sure that the LFU is in Step 4
reference cylinder. - Keep the Measuring tool assembled during the setting.
- Loosen the Screw for the Outer bearing half and the Outer bearing half.

- Measuring tool
- Screw
- Outer bearing half
- Outer bearing half
- Middle bearing half
- Set the Middle bearing half according to the value obtained from the Procedure-section Check the Gap between Bearing Halves and Mandrel Shaft.
- Valid for: Barrier nut and flange nutLoosen the Screw.
- Set the Middle bearing half by loosening or tightening the Flange nut.Note: Do not use the Barrier nut for the setting, the Barrier nut is a lock nut.
- If the Spacer turns during the setting and if the Middle bearing half do not move, change the sheet and the spacer. See Procedure Frame - Change Sheet and Spacer.
- Tighten the Screw to 10 Nm to 12 Nm.
- Set the Outer bearing half and the Outer bearing half. See Procedure-section Set the Outer Bearing Halves.
- Valid for: Plate and nutLoosen the Nut.
- Set the Middle bearing half by loosening or tightening the Plate.
- If the Spacer turns during the setting and if the Middle bearing half do not move, change the sheet and spacer. See Procedure Frame - Change Sheet and Spacer.
- Tighten the Nut to 100 Nm.
- Set the Outer bearing half and the Outer bearing half. See Procedure-section Set the Outer Bearing Halves.

Barrier nut and flange nut

Plate and nut
- Screw
- Barrier nut
- Flange nut
- Spacer
- Nut
- Plate
Set the Outer Bearing Halves
- Make sure that the Middle bearing half is adjusted.
- Make sure that the LFU is in Step 4
reference cylinder. - Keep the Measuring tool assembled during the setting.

- Middle bearing half
- Measuring tool
- Make sure that the Screw for the Outer bearing half are loosened.
- Adjust the Outer bearing half according to the value obtained from Procedure Section Check the Gap between Bearing Halves and Mandrel Shaft. The raise on the Outer bearing half must be 0.2.
- To adjust up or down, tap gently with a rubber club either on the Rod end or on the Edge of the Outer bearing half.

- Rod end
- Outer bearing half
- Edge
- Screw
- Tighten the Screw in steps to 206 Nm.Note: It is important that the force is applied horizontally and in limited movements of about 60°. If the force is applied in a different angle, it can unintentionally change the height of the Outer bearing half.
- Check the gap. See Procedure-section Check the Gap between Bearing Halves and Mandrel Shaft.
- Repeat items Reference to Reference for the other outer bearing half.

A = 30º
- Screw
Check the Initial Cavity
Set the LFU to achieve the correct initial cavity.- Make sure that the pair of tools is centred toward external tools. See Procedure External Tools - Set Centre of Tools.
- For screw cap C38/O38 tools with FIXED bushing, go to item Reference.
- Run at least two sleeves.
- For screw cap C38 tools with Spring-Loaded bushing, install Template [1] on a pair of mandrels.
- Put sleeves on a pair of mandrels.
- Put grease on two pieces of tin solder, each tin solder being 1.5 mm thick and 5mm long.
- Put the pieces of tin on the pair of the internal tools or templates that have the sleeves (see pointer arrows). Do not put the tin on engraved text or plugs. See the illustration for the correct placement of the tin.

PullBridge

Spiral

BridgeTwist

A38

O38/C38 with FIXED bushing

C38 with Spring-Loaded bushing, Template [1]

Huron

Saroma

Lokka
Risk of crushingBe careful when working near the moving parts. Use trained personnel when working with the LFU unit in service position.The machine contains moving parts that can crush.
Hot surfacesThe hot channel and the extruder can be hot.Risk of burns.
Oil under pressureUse protective goggles when working near and around the
LFU unit. Check the condition of the hydraulic hoses and connections before setting the machine into service mode. If necessary, change the hoses. See Procedure
Hydraulic System LFU - Change Hydraulic Hoses.Risk of eye injury.
- Turn the pair of mandrels downwards.
- Use the remote control. See Procedure LFU Remote Control - Handle. Start:
- Step 1 Hydraulic High Pressure
- Step 2 Locking Scissors
- Close tools manually with the recharging valve on the hydraulic block.
- Step 3 Horizontal Force
- Step 4 Reference Cylinder
- Step 5 Tightness
- Deactivate in the reverse order.
- Check the 1.5-mm tin solder thickness with a micrometre. For the acceptable thickness values, see Chapter Tools LFU. If the thickness of the tin is out of range, see Procedure-section Set the Initial Cavity.
Set the Initial Cavity
- Remove the Screw, the Washer, and the Bronze washer.Note: Handle the Washer with care.
- Measure the thickness of the Bronze washer.Note: If the thickness is less than or equal to 4.9 mm, change the Screw and both the Bronze washer with new ones.
- Apply a thin layer of antiseize on the flat surfaces of the Bronze washer.
- Assemble in the reverse order.
- If the Screw and the Bronze washer have been changed, according to item Reference; Check the initial cavity. See Procedure-section Check the Initial Cavity.
- If the Initial cavity is not correct; add or remove Shim.Note: Adding Shim increases the initial cavity and the final cavity.Note: Always put the thickest Shim on top of the shim bundle.
- If Shim or Bronze washer have been changed; set the distance between the hanger and the reference stop. See Procedure-section Set Distance between Hanger and Reference Stop.
- Repeat on the other side.

- Screw
- Washer
- Bronze washer
- Shim
Set Distance between Hanger and Reference Stop
- Loosen the Screw. Put two Feeler gauge between the Outer bearing half and the shims as shown in the illustration.Note: Use the correct feeler gauge depending on lid forming tools. See the table.
- Loosen the counter nut on the Screw (Hex key No. 5). Adjust the Screw (Hex key No. 5) until the Feeler gauge are tight (use a 5-mm hex key).
- Tighten the counter nut on the Screw (Hex key No. 5). Remove the Feeler gauge.Note: Make sure that the distance achieved by the Feeler gauge does not change during tightening of the counter nut.
| Lid forming tool | Feeler gauge (mm) |
| C38 with spring-loaded bushing | 0.8 |
| Other tools | 0.6 |

- Feeler gauge
- Screw
- Outer bearing half
- Screw (Hex key No. 5)
- To centre the Outer bearing half, use a Crowbar to lift the Reference stop until it touches the Mandrel wheel. Tighten the Screw while holding the Reference stop against the Mandrel wheel.
- Repeat items Reference to Reference for the other outer bearing half.
- Check the initial or final cavity according to Procedure-section Check the Initial Cavity or Check the Final Cavity.

- Screw
- Outer bearing half
- Reference stop
- Crowbar
- Mandrel wheel
Check the Final Cavity
The final cavity check is a confirmation that the internal tools do not meet the external tools.- Make sure that the pair of tools is centred toward external tools. See Procedure External Tools - Set Centre of Tools.
- For screw cap C38/O38 tools with FIXED bushing, go to item Reference.
- Run at least two sleeves.
- For screw cap C38 tools with Spring-Loaded bushing, install Template [1] on a pair of mandrels.
- Put sleeves on a pair of mandrels.
- Put grease on two pieces of tin solder, each tin solder being 1.5 mm thick and 5mm long.
- Put the pieces of tin on the pair of the internal tools or templates that have the sleeves (see pointer arrows). Do not put the tin on engraved text or plugs. See the illustration for the correct placement of the tin.

PullBridge

Spiral

BridgeTwist

A38

O38/C38 with FIXED bushing

C38 with Spring-Loaded bushing, Template [1]

Huron

Saroma

Lokka
Risk of crushingBe careful when working near the moving parts. Use trained personnel when working with the LFU unit in service position.The machine contains moving parts that can crush.
Hot surfacesThe hot channel and the extruder can be hot.Risk of burns.
Oil under pressureUse protective goggles when working near and around the
LFU unit. Check the condition of the hydraulic hoses and connections before setting the machine into service mode. If necessary, change the hoses. See Procedure
Hydraulic System LFU - Change Hydraulic Hoses.Risk of eye injury.
- Turn the mandrels downwards.
- Use the remote control. See Procedure LFU Remote Control - Handle. When the LFU is up in working temperature, start:
- Step 1 Hydraulic High Pressure
- Step 2 Locking Scissors
- Close tools manually with the recharging valve on the hydraulic block.
- Step 3 Horizontal Force
- Step 4 Reference Cylinder
- Step 5 Tightness
- Step 6 Pressing
- Deactivate in reverse order.
- Check the tin solder thickness with a micrometer. The thickness must be as indicated in the table:
| Lid forming tool | Thickness (mm) |
| All tools | 0.15 to 0.30 |
- If the values are out of range, perform a new setting according to Procedure-section Set the Initial Cavity. After that, repeat the final cavity check.
Check the Gap between Reference Stop and External Tools
Risk of crushingBe careful when working near the moving parts. Use trained personnel when working with the LFU unit in service position.The machine contains moving parts that can crush.
Hot surfacesThe hot channel and the extruder can be hot.Risk of burns.
Oil under pressureUse protective goggles when working near and around the
LFU unit. Check the condition of the hydraulic hoses and connections before setting the machine into service mode. If necessary, change the hoses. See Procedure
Hydraulic System LFU - Change Hydraulic Hoses.Risk of eye injury.
- Make sure that the mandrel wheel and the External tool do not collide.
- Use the remote control. See Procedure LFU Remote Control - Handle. Start:
- Step 1 Hydraulic High Pressure
- Step 2 Locking Scissors
- Close tools manually with the recharging valve on the hydraulic block.
- Step 3 Horizontal Force
- Step 4 Reference Cylinder
- Install the Template 2799379-0000 during external tools closed. See Procedure-section Check the Gap between Hot Channel and External Tools.Note: If the hydraulic pressure drops to 0 bars in the same way as if; the EMERGENCY STOP button is pressed, or the hydraulic oil temperature reaches its alarm lever, or power failure on the machine, and so on, the external tools open without warning.
- Check the gap C between the Reference Stop and the External tool with a feeler gauge.
- The gap C must be within range in one position on each pair of the External tool. If it is not, see Procedure-section Set the Hanger.Note: If the difference between the two values on one pair of tools is not according to gap C, check that the tools are correctly installed. See Procedure . If the difference between the values still is too great, set the carriage according to Procedure , items to .
- Reference Stop
- External tool
Set the Hanger
- Remove the Screw. Add/remove Shim. Adding shims increases the gap C between the Reference stop and the External tool.Note: Put the thinnest shim in the middle of the shim bundle and the thickest shim on top of the shim bundle.
- Check the gap between the reference stop and the bearing half. See Procedure-section Check the Gap between Reference Stop and External Tools.

- Screw
- Shim
- Reference stop
- External tool
- Hanger
Check the Gap between Hot Channel and External Tools
Risk of crushing and cutting.Enclose the area around the LFU and make sure that no unauthorised personnel can come in contact with the LFU.The movement in the LFU can cause injuries.
Hot surfacesThe hot channel and the extruder can be hot.Risk of burns.
Oil under pressureUse protective goggles when working near and around the
LFU unit. Check the condition of the hydraulic hoses and connections before setting the machine into service mode. If necessary, change the hoses. See Procedure
Hydraulic System LFU - Change Hydraulic Hoses.Risk of eye injury.
- Make sure that the mandrel wheel and the external tools do not collide.
- Use the remote control. See Procedure LFU Remote Control - Handle. Start:
- Step 1 Hydraulic High Pressure
- Step 2 Locking Scissors
- Close tools manually with the recharging valve on the hydraulic block.
- Put the Template, TP No 2799379-0000 between the Holder.
- Step down until Hydraulic High Pressure is on. You may help to open the scissor manually.The Holder are now in a locked position, and leave a gap between the external tools.Note: Hydraulic High Pressure must be activated, and the distance cylinders must be active to get a correct value.

- Template
- Holder
- Measure the gap A between the Hot channel and the External tool with a feeler gauge.Note: The gap A must be measured with the LFU preheated.Note: The surface on the Hot channel must be clean.
- If the gap A is out of range, remove the Template, TP No 2799379-0000, according to items Reference to Reference. Then adjust the gap A according to Procedure-section Set the Gap between Hot Channel and External Tools.
- Use the remote control. See Procedure LFU Remote Control - Handle.
- Start:
- Step 1 Hydraulic High Pressure
- Step 2 Locking Scissors
- Close the tools manually, and hold them in this position.
- Remove the template.
- Template, TP No 2799379-0000
- Hot channel
- External tool
Set the Gap between Hot Channel and External Tools
- Use the remote control to step down until Hydraulic High Pressure is off.
- Deactivate the service key.Note: When the service key is deactivated, the hydraulic unit stops and the LFU is nonpressurised.
- Remove the Screw and the Spacer.
- Add/remove Shim.Note: Removing shims decreases the gap A, with a risk for collision between the Hot channel and the External tool.Note: To get a safe initial gap A, add a Shim, so that the distance B is achieved.
- Repeat the check, in Procedure-section Check the Gap between Hot Channel and External Tools, until the gap A is within range.
- Check the support to the reference stop. See procedure LFU - Set Support to Reference Stop.
- Screw
- Spacer
- Shim
- Hot channel
- External tool
LFU - Set Support to Reference Stop
| Equipment Status | Program Step |
| Special Equipment | Measuring Instrument, TP No. 1567930-0101 |
Risk of injuryBe careful when working near the shims.The shims in the LFU could be sharp.
Check
- Set the mandrel wheel in a cross position so it is positioned away from the external tools.Note: The measuring point on the reference stop is on the side of the Steel washer, front and rear.
- Activate step 3 (horizontal force) to close the external tools, see ProcedureLFU Remote Control - Handle.
- Mount the Dial indicator at the measuring point.
- Activate step 5 (tightness).
- Set the Dial indicator to zero.
- Activate step 4 (reference cylinder) and read the dial indicator.Note: Maximum sideways play must be reduced to less than 0.10 mm. If necessary, set the support.

- Steel washer
- Dial indicator
Set
- Loosen the counter nuts on the Adjusting screw.
- Loosen the Vertical screw.
- Adjust Adjusting screw and repeat item Reference and Reference until the correct value is reached.
- Tighten the Vertical screw to 50 Nm.
- Tighten the counter nuts.
- Repeat the check again.

- Vertical screw
- Adjusting screw
LFU - Set Homing Position
| Equipment Status | Program Step |
| Special Equipment | Keyboard |
Risk of injuryBe careful when working near the shims.The shims in the LFU could be sharp.
Risk of damage to the equipment.Make sure that the
Mandrel are aligned in a 90° position before setting the homing position.The
Mandrel must be aligned in a 90° position, otherwise the
Mandrel and the external tools can collide.
- For tools with FIXED bushing, go to item Reference.
- For all other tools:Note: For correctly performed homing, the Sleeve must be fitted on the mandrels pointing downwards.
- Align the Mandrel manually in a 90° position with the Sleeve pointing downwards.

- Sleeve
- Mandrel
- Connect a keyboard to the TPOP.
- Open the Technical Menu by pressing the f4 button on the keyboard.
- Open the Servo Technical window by pressing the Servo button.

- Servo button
- Reset the home position by pressing the Reset button, S1 or the Reset button, S2 button.
- Exit the Servo Technical window and the Technical Menu.
- Step the machine up to air on. An alarm regarding servo motor position starts.
- Reset the alarms.
- Open the Technical Menu by pressing the f4 button on the keyboard.
- Open the Servo Technical window by pressing the
Servo. - perform the calibration by pressing the Calibrate button, S1 or the Calibrate button, S2 button.Note: When the homing is activated, the external tools close and the mandrels are aligned in the correct position to be homed. The PLC program performs all automatically.
- Exit the Servo Technical window and the Technical Menu. Press save before you exit and the servo motor position alarm stops.

- Reset button, S1
- Reset button, S2
- Calibrate button, S1
- Calibrate button, S2
LFU - Move to Service Position
| Equipment Status | Program Step HEATING |
| Special Equipment | Rail TP No. 915399-0002 Hydraulic hose TP No. 3019750-0000 Hydraulic hose TP No. 3019751-0000 Crowbar |
Risk of injuryBe careful when working near the shims.The shims in the LFU could be sharp.
Heavy equipmentIt is recommended to be two people when handling the footstep. Handle the footstep with care and make sure that you take precautions to handle the weight.The footstep is heavy and can cause personal injuries and damage to equipment.
- Run at least eight Mandrel with sleeve and put them on the mandrels to avoid damaging the tools and mandrels.
- Step the machine down to step zero.
- Dismantle the emergency stop wire at the rear end and measure the setting distance to facilitate the assembly.
- Disconnect the cable connections from the lower door safety switches.
- Remove the doors at the front of the LFU, the hydraulic unit, and the cooling water unit, by pushing out the hinge dials from underneath and then remove the hinge holders, (down left on side 1 and down right side on side 2).
- Remove the beam at the front of the LFU and the beam holder.

- Mandrel with sleeve
- Close the Valve on the Granulate hose.
- Disconnect the Granulate hose from the Dosing unit. Collect the residual granulate in a vessel to prevent spill.Note: Cover the granulate inlet hole while working with the LFU.
- Disconnect the Screw from the Stripper link arm.
- Valid for: LFU with Sleeve StopPull the Knob to release the Sleeve stop plate.

- Screw
- Stripper link arm
- Dosing unit
- Knob
- Granulate hose
- Valve
- Sleeve stop plate
Valid for: Equipment with CAU- Remove the chute:

- Chute
- Photocell
- Chute
- Screw
- Loosen the Screw and remove the Bracket.Note: Do not remove the cables from the Bracket, remove only the bracket from the LFU.
- Disconnect the servomotor Cable connection for the mandrel wheel and the servomotor Cable connection for the tool movement.Note: Be careful with the cables, otherwise errors caused by missed signals between the PLC and the servomotor can occur. This type of errors is often intermittent.
- Remove the footstep at the front of the LFU.Note: When you remove the screws from the footstep, it falls down unless you support it. Support the footstep manually, or use a rail.

- Cable connection
- Bracket
- Screw
- Cable connection
Risk of crushing.Make sure that the actions in items
Reference to
Reference are performed.If the actions in items
Reference to
Reference are not performed, the
LFU can fall down. This can lead to personal injuries and major mechanical damage.
Heavy equipmentIt is recommended to be two people when handling the rails. Handle the rails with care and make sure that you take precautions to handle the weight.The rails are heavy and can cause personal injuries and damage to equipment.
Note: The carriage for LFU rails can be used when handling the Rail. see Procedure on page .- Fit the Rail on the Centring pin and secure with the Screw (M8x16) from the footstep.
- Tighten the Screw by hand.
- Set the Leg and make sure that the Rail are in level and parallel to each other. If necessary, use blocks under the Leg. When the Rail are positioned correctly, tighten the Screw.

- Centring pin
- Rail
- Screw
- Leg
Risk of fallingSweep the floor immediately to avoid injuries.If hydraulic oil is spilled on the floor, the floor can be slippery.
- Disconnect the Hydraulic hose.
- Remove the Screw.
- Remove the four bar Nut.

- Screw
- Hydraulic hose
- Nut
Heavy equipment.Handle the LFU with care and make sure that you take precautions to handle the weight.The LFU is heavy and can cause personal injuries and damage to equipment.
- Use a crowbar, placed between the top of the LFU and the frame, to lift the unit off the centring pins in the main machine.Note: Be careful not to damage the cables, the pipes, and the hoses when pulling out the LFU.
- Roll the LFU carefully out to its service position.Connect the extension Hydraulic hose.Note: Check the condition of the hydraulic hoses and connections before setting the machine into service mode.

- Hydraulic hose
LFU - Remove from Machine
| Equipment Status | Program Step |
| Special Equipment | Rail, TP No. 915399-0002 Forklift |
Risk of injuryBe careful when working near the shims.The shims in the LFU could be sharp.
- Follow the ProcedureLFU - Move to Service Position.
- Disconnect the Lubrication hose, cooling Water hose, and the Pneumatic hose from the distribution block.
- Remove the Cable connection for the transfer unit.

- Lubrication hose
- Water hose
- Pneumatic hose
- Cable connection
- Place two Pallet under the LFU.
Heavy equipment.Handle the LFU with care and make sure that you take precautions to handle the weight.The LFU is heavy (approximately 1300 kg) and can cause personal injuries and damage to equipment.
Use a forklift to remove the LFU from the Rail.
- Pallet
- Rail
LFU - Install from Service Position
| Equipment Status | Program Step STEP ZERO |
| Special Equipment | Rail: TP No. 915399-0002 |
| Consumables | Anti-seize: TP No. 344418-0000 |
Risk of injuryBe careful when working near the shims.The shims in the LFU could be sharp.
Risk of fallingSweep the floor immediately to avoid injuries.If hydraulic oil is spilled on the floor, the floor can be slippery.
- Disconnect the extended hydraulic hoses.
Risk of crushing.Make sure that the actions in Items
Reference are performed.If the actions in Item
Reference is not performed, the
LFU can fall down. This can lead to personal injuries and major mechanical damage.
Make sure that the Wheel shaft are properly tightened.
- Wheel shaft
Heavy equipment.Handle the LFU with care and make sure that you take precautions to handle the weight.The LFU is heavy and can cause personal injuries and damage to equipment.
- Roll the LFU unit carefully into position and make sure that the centring pins fit.Note: Be careful not to damage the cables, the pipes, and the hoses when rolling the LFU into place.
- Apply the anti-seize on the bars, the washers, and the Nut and Screw. Tighten all the nuts crosswise.
- Connect the Hydraulic hose.

- Nut
- Screw
- Hydraulic hose
- Connect the Granulate hose to the Dosing unit.Note: It is important that the distance A is maximum 100 mm, otherwise there is a risk of granulate stagnation in the Granulate hose.
- Open the Valve for the granulate.
- Pull the Knob and fasten the Sleeve Stop plate.Note: Make sure that the Sleeve Stop plate is properly secured, see .
- Fit the Stripper link arm with the Screw.

A (mm) = Max 100
- Granulate hose
- Dosing unit
- Valve
- Stripper link arm
- Screw
- Knob
- Sleeve Stop plate
- Connect the servo motor Cable connection and Cable connection.
- Assemble the Bracket and the Screw.
- Assemble the Bracket and tighten the Screw.

- Cable connection
- Cable connection
- Bracket
- Screw
- Bracket
- Screw
Heavy equipmentIt is recommended to be two persons when handling the rails. Handle the rails with care and make sure that you take precautions to handle the weight.The rails are heavy and can cause personal injuries and damage to equipment.
Note: The carriage for LFU rails can be used when handling the Rail. See Procedure on page .- Remove the Screw and the Rail and fit the Beam at the front of the LFU.Note: Make sure that the Regulator is not covered by the Beam.
- If necessary, adjust the position of the Regulator by adjusting the Beam. If this is not enough, adjust the Screws.

- Screw
- Rail
- Beam
- Regulator
- Screws
- Assemble the footstep and the doors in front of the LFU.
- Assemble the safety door guards and the emergency stop wire.
- Check the function of the safety door guards and the stop wire. See Procedure TT/3 Emergency Stop Button/Cord - Check on page TT/3 Emergency Stop Button/Cord - Check.
- Perform a homing. See Procedure LFU - Set Homing Position on page LFU - Set Homing Position.Assemble the chute (CAU equipped machines):
- Put the Chute back and tighten the Screw.
- Attach the Chute to the Chute and tighten the Nut.
- Set the Knife. See Procedure Duct - Set Knife on page Duct - Set Knife.

- Chute
- Screw
- Chute
- Nut
- Knife
LFU - Install to Machine
| Equipment Status | Program Step STEP ZERO |
| Special Equipment | Rail: TP No. 915399-0002 Forklift Pallets |
| Consumables | Anti-seize: TP No. 344418-0000 |
Risk of injuryBe careful when working near the shims.The shims in the LFU could be sharp.
Heavy equipmentIt is recommended to be two persons when handling the rails. Handle the rails with care and make sure that you take precautions to handle the weight.The rails are heavy and can cause personal injuries and damage to equipment.
Risk of crushingMake sure that the actions in Items
Reference to
Reference are performed.If the actions in Items
Reference to
Reference are not performed, the
LFU can fall down. This can lead to personal injuries and major mechanical damage.
Note: The carriage for LFU rails can be used when handling the Rail. See Procedure.- Make sure that the Wheel are properly tightened.
- Fit the Rail on the Guide pin.
- Secure the Rail to the frame by tightening the Screw.
- Make sure that the Rail are parallel and in level. If necessary, adjust the height on the Leg.

- Wheel
- Rail
- Guide pin
- Screw
- Leg
Heavy equipment.Handle the LFU with care and make sure that you take precautions to handle the weight.The LFU is heavy (approximately 1300 kg) and can cause personal injuries and damage to equipment.
- Place the LFU on two Pallet.
- Use a forklift to place the LFU on the Rail.Note: Make sure that the Wheel are placed on the Rail .Note: Be careful not to damage the cables, the pipes, and the hoses when rolling the LFU unit into place.
- Roll the LFU carefully into position and make sure that the centring pins fit.

- Wheel
- Rail
- LFU
- Pallet
- Apply the anti-seize on the bars, the washers, and the Nut and Screw. Tighten all the nuts crosswise.
- Connect the Hydraulic hose, Cooling water hose, Pneumatic hose, and Lubrication hose.
- Connect the Cable connection for the transfer unit.Complete the installation. See Procedure LFU - Install from Service Position on page LFU - Install from Service Position and start from item Reference.

- Nut
- Screw
- Hydraulic hose
- Cooling water hose
- Pneumatic hose
- Lubrication hose
- Cable connection
LFU Remote Control - Handle
| Equipment Status | Program Step |
| Special Equipment | Protective goggles TP No. 90303-0011 Template, TP No. 2799379-0000 |
Risk of injuryBe careful when working near the shims.The shims in the LFU could be sharp.
Oil under pressureUse protective goggles when working near and around the LFU unit. Also check the condition of the hydraulic hoses and connections before setting the machine into service mode. If necessary, change the hoses.Risk of eye injury.
- Insert and activate the service key and the Service window appears.Note: To be able to use and run theService window functions, at least one door in carton section must be open.
- Choose LFU Service (S1) or LFU Service (S2):
- The hydraulic unit starts, which means that low hydraulic pressure is available.
- The window Service functions LFU G2 appears, see next page.

- Service window
- LFU Service (S1)
- LFU Service (S2)
Risk of crushing and cutting.Enclose the area around the LFU and make sure that no unauthorized personnel can come in contact with the LFU.The movement in the LFU can cause injuries.
It is now possible to handle the Remote Control.- Press the Button STEP UP button.
- Press the Button STEP DOWN button.
- Press Button ACTIVATE to activate the selected step.

- Remote Control
STEP UPButton STEP DOWNButton ACTIVATEButton
- Template, TP No 2799379-0000 should be used during all maintenance sequence with external tools closed
- Put the Template, TP No 2799379-0000 between the Holder.
- Step down until High Pressure is on. You may need to help open the scissors.The Holder are now in a locked position, and leave a gap between the external tools.

- Template, TP No 2799379-0000
- Holder
Description of the LFU steps
LFU - Gearbox Oil Table
Risk of injuryBe careful when working near the shims.The shims in the LFU could be sharp.

- Planetary Gear (Mandrel Wheel)
- Planetary Gear (Tool Drive)
- Geared Motor (Transfer Unit)
LFU - Install/Remove Rails with Carriage
| Equipment Status | Program Step STEP ZERO |
| Special Equipment | Rail: TP No. 915399-0200 Carriage for LFU Rails: TPNo.3416603-0100 |
Risk of injury.Be careful when working near the shims.The shims in the LFU could be sharp.
Heavy equipment.It is recommended to be two persons when handling the rails. Handle the rails with care and make sure that you take precautions to handle the weight.The rails are heavy and can cause personal injuries and damage to equipment.
Risk of crushing.Make sure that the actions in Items
Reference to
Reference are performed.If the actions in Items
Reference to
Reference are not performed, the
LFU can fall down. This can lead to personal injuries and major mechanical damage.
- Make sure that the Carriage for LFU rails are in their lowest position. Lower the Carriage for LFU rails with the Handle.Note: The Handle can be assembled on either side of the Carriage for LFU rails.

- Handle
- Carriage for LFU rails
- Place the Rail in the Carriage for LFU rails. Make sure that the Guide hole is in the same direction as the Arrow.
- Transport the Rail to the LFU.

- Rail
- Guide hole
- Arrow
- Lower the Carriage for LFU rails and slide the Rail in under the LFU.
- Fit the Rail on the Guide pin.Note: If necessary, to reach the Guide pin, tilt the rails in the carriages by pushing down the rail ends with the Leg.
- Manually secure the Rail to the frame, with the M8 Screw from the footstep.
- Make sure that the Rail are parallel and in level. If necessary, adjust the height on the Leg.
- Tighten the Screw.
- Remove the Rail in the reverse order.

- Carriage for LFU rails
- Rail
- Guide pin
- Screw
- Leg
LFU Remote Control - Handle
| Equipment Status | Program Step |
| Special Equipment | Protective goggles, TP No. 90303-0011 Locking Loop, TP No. 3674453-0000 |
Risk of injuryBe careful when working near the shims.The shims in the LFU could be sharp.
Oil under pressureUse protective goggles when working near and around the LFU unit. Also check the condition of the hydraulic hoses and connections before setting the machine into service mode. If necessary, change the hoses.Risk of eye injury.
- Insert and activate the service key and the Service window appears.Note: To be able to use and run the Service window functions, at least one door in carton section must be open.
- Choose LFU Service (S1) or LFU Service (S2):
- The hydraulic unit starts, which means that low hydraulic pressure is available.
- The window Service functions LFU G2 appears.

- Service window
- LFU Service (S1)
- LFU Service (S2)
Risk of crushing and cutting.Enclose the area around the LFU and make sure that no unauthorized personnel can come in contact with the LFU.The movement in the LFU can cause injuries.
It is now possible to handle the Remote Control.- Press the Button STEP UP button.
- Press the Button STEP DOWN button.
- Press Button ACTIVATE to activate the selected step.

- Remote Control
STEP UPButton STEP DOWNButton ACTIVATEButton
- The Locking Loop should be used during all maintenance sequence with external tools closed.
- Install the Locking Loop in the Hole in the Scissor and lock it with the Pin.
- Step down until High Pressure is on.

- Locking Loop
- Hole
- Scissor
- Pin
Description of the LFU steps
Mandrel Wheel/Bearing House
Mandrel Wheel - Check Oil Leakage
| Equipment Status | Program Step STEP ZERO |
- Check visually if there is any oil leakage from the Planetary gear.
- If there is a leakage, change the gear. For more information, see Procedure 3.2-10 LFU - Gearbox Oil Table.

- Planetary gear
Mandrel Wheel - Change Servo Motor
| Equipment Status | Program Step STEP ZERO |
| Consumables | Decreasing Compound Thread locker: TP No 351532-0000 |
- Pull out the LFU. See Procedure LFU - Move to Service Position.Note: Make sure to disconnect the Cable Connection for the Servomotor.
- Loosen the two screws in the Clamping Hub through the Hole.
- Remove the Screws and pull out the Servomotor.
- Clean the new servomotor Shaft with degreasing compound.Note: It is important to do this carefully to avoid skid between clamping hub (6) and the servomotor Shaft.
- Align the Clamping Hub so that its screws can be reached through the Hole.
- Apply thread locker on the Screws, assemble the Servomotor and tighten with 22 Nm.
- Tighten the screws for the Clamping Hub in a crosswise sequence. See the table below.
| Valid for Planetary Gear 90459-3046 | Valid for Planetary Gear 90606-3408 |
| Final tightening torque | 9.5Nm | 14Nm |
| Key width | 4mm | 5mm |
- Fit the LFU back. See Procedure LFU - Install from Service Position, connect the Cable Connection.
- Perform a homing. See Procedure LFU - Set Homing Position.

- Hole
- Shaft
- Cable Connection
- Screws
- Servomotor
- Clamping Hub
Mandrel Wheel - Change Planetary Gear
| Equipment Status | Program Step STEP ZERO |
| Consumables | Thread locker: TP No 351532-0000 |
- Pull out the LFU. See Procedure LFU - Move to Service Position.Note: Don’t forget to disconnect cables (3) for servomotor (5)!
- Remove the servomotor, see Procedure Mandrel Wheel - Change Servo Motor.
- Remove the Screw and the Bearing Half.
- Remove theScrew, rotate the mandrel wheel to reach all.
- Remove the Screw and pull out the Planetary Gear.
- Remove the Screw and the Flange.
- Apply thread locker on the Screw, assemble the Flange on the new Planetary Gear, tighten with 22 Nm.Note: The recess in the Flange shall be directed toward the Planetary Gear!
- Assemble the Planetary Gear, fit the Screw and Screw. Tighten the Screw and Screw.Note: Align the holes in the Planetary Gear upwards and downwards
- Assemble the Bearing Half and the screws, tighten with 45 Nm.
- Assemble the servomotor, see Procedure Mandrel Wheel - Change Servo Motor.
- Fit the LFU, see Procedure LFU - Install from Service Position, connect the cables (3).
- Perform a homing, see Procedure LFU - Set Homing Position.

- Screw
- Bearing Half
- Screw
- Planetary Gear
- Screw
- Screw
- Flange
Mandrel Wheel - Change Bar
| Equipment Status | Program Step |
| Special Equipment | Torque wrench |
Roll out the LFU, see Procedure LFU - Move to Service Position.Note: Always change the bars in pairs.Outer Bars:
- Remove the Screws and the Outer bearing half.
- Loosen Screws.
- Remove the Outer bar.Note: To be able to remove the bars closest to the machine, remove the floor plate above the bars.
- Change the Outer bar.
- Assemble in the reverse order. Tighten the screws according to the table, Torque Outer bars.
- Set the height, see Procedure LFU - Basic Set.
| Torque Outer bars |
| Screws no. | Torque (Nm) |
| (1) | 79 |
| (3) | 206 |

- Screws
- Outer bearing half
- Screws
- Outer bar
Middle Bars
- Remove the Screws and the outer bearing halve (6).
- Remove Screws.
- Remove the Middle bar.
- Change the Middle bar.
- Assemble in the reverse order. Tighten the screws according to the table, Torque Middle bars.
| Torque Middle bars |
| Screws no. | Torque (Nm) |
| (5) | 296 |
| (7) | 296 |

- Screws
- Middle bearing half
- Screws
- Middle bar
Connection - Check
| Equipment Status | Program Step |
| Special Equipment | Measuring Instrument, TP No. 1567930-0101 |
If the run-out tolerance is more than the recommended it can affect the bearing installation and the sealings in the Connection with a water leakage as a result. - Make sure that the stripper is free from the mandrels.
- Check the run-out tolerance at the end of the Connection (diameter 40 mm), recommended run-out is 0.02 mm.
- If the run-out tolerance is more than recommended, see Procedure Connection - Set.

- Connection
Swivel/Connection - Check Lid Blower (Festo, Mecman)
| Equipment Status | Program Step |
- Valid for FestoCheck for air leakage on the lid blowing Cylinder. On Festo machines, use the air service tool. See Air Service Tool Description
- Listen for air leakage in the Cylinder, especially when the Cylinder is in the + position.

- Cylinder
Valid for MecmanCheck for air leakage on the lid blowing Cylinder.Note: Two persons are required to perform this procedure.- Force valve A30K1230 (S1), or alternatively, A30K2230 (S2) on the Pneumatic panel, listen for air leakage in the Cylinder, especially when the Cylinder is in the + position.
- Force valve A30K1230 (S1), or alternatively, A30K2230 (S2) on the Pneumatic panel, and use a hand to feel if there is any air blowing out of the cylinder, especially when the Cylinder is in the + position.
- Check for wear on the O-ring, and check that the O-ring is properly fitted. Change if required, see chapter Swivel/Connection - Change Sealings.Note: It is not necessary to remove the Lid blower from the Swivel to check the O-ring. See Procedure .
- Assemble and set the lid blower according to Procedure Swivel/Connection - Set Lid Blower.

- Cylinder
- Pneumatic panel
- Lid blower
- Swivel
- O-ring
Connection - Set
| Equipment Status | Program Step |
| Special Equipment | Measuring Instrument, TP No. 1567930-0101 |
| Consumables | Loctite 243 TP No. 344431-0000 |
If the run-out tolerance is more than the recommended it can affect the bearing installation and the sealings in the Connection with a water leakage as a result. Therefore it is advisable to aim for a run-out as low as possible.If the run-out tolerance is more than recommended, do as follows:- Increase the torque on one or more of the Screw, meanwhile check the measuring instrument if the run-out tolerance is affected.Nominal torque is 22 Nm, not more than 25 Nm is recommended.
- If this does not work, loosen all the Screw and tighten them with different torque until the run-out tolerance is as low as possible.This technique can lead to a torque for one or more of the Screw to be beneath 22 Nm, secure those Screw with Loctite 243.

- Screw
- Connection
Swivel/Connection - Set Lid Blower
| Equipment Status | Program Step |
| Special Equipment | Sliding Caliper |
Lid Blower Set
- Adjust the Holder on the Swivel to the distance A, tighten the Counter Nut.
- Adjust the Plunge on the Cylinder so that the distance B is obtained, tighten the Counter Nut.Note: The Plunge shall be in its inner position, see arrow in illustration.
- Fit the Cylinder (with the Plunge) in the Holder, assemble the Washer and the Connection.
- Adjust to the distance D, tighten the Counter Nut.The above settings are done to achieve gap C, so that the Mandrel Wheel goes free from the Plunge during rotation.
- Align the air hoses so that they are pointing downwards. Note: Slide the plunge backward and forward to its end position and check so that Washer not strikes Holder!
- Fit the air hoses to the Lid Blower. Note: Make sure that no sideway forces are added. Sideway forces increase the wear on the Washer.

A (mm) = 93.5 ±1.5
B (mm) = 129 ±0.5
C (mm) = 3.0 ±1.0
D (mm) = 10.0 ±1.0
- Lid Blower
- Swivel
- Counter Nut
- Connection
- Washer
- Holder
- Plunge
- Counter Nut
- Cylinder
- Mandrel Wheel
- Counter Nut
Swivel/Connection - Fit
| Equipment Status | Program Step STEP ZERO |
| Consumables | Grease: TP No. 344407-0000 |
- Assemble the Pipe.
- Assemble the Tube in the Connection.
- Slide the Ring and the Connection on to the mandrel.Note: During this assembling, make sure that the Tube are aligned and fitted between the Connection and the mandrel.
- Assemble the Washer and the Screw. Tighten crosswise in steps to a final torque of 22 Nm.Note: It is important that the Connection is carefully aligned to the mandrel shaft, otherwise a future water-leakage can occur. If there is a need for check, see .
- Make sure that the Bracket is correctly aligned against the Swivel, by checking that the distances A and B are the same.
- If necessary, loosen the Screw and adjust the distances. Tighten the Screw.
- Apply a thin layer of grease on the Connection and slide on the Swivel. Align the Bracket in to the Pin.
- Assemble the Washer and the Screw. Tighten the Screw crosswise.
- Assemble the Water Hose and the Air Hose.
- If there is need for adjusting the lid blower, see Procedure Swivel/Connection - Set Lid Blower.
- Put the cooling water hoses back for the LFU (15).

- Screw
- Washer
- Swivel
- Water Hose
- Air Hose
- Screw
- Bracket
- Pin
- Screw
- Washer
- Connection
- Ring
- Tube
- Pipe
- Cooling Water Connection
Hanger Tool - Change Distance Cylinder
| Equipment Status | Program Step STEP ZERO |
| Special Equipment | Puller: TP No. 1573180 Puller: TP No. 1573181 |
| Consumables | Thread locker: TP No. 351532-0000 |
Risk of injuryBe careful when working near the shims.The shims in the LFU could be sharp.
- Remove the Screw, Spacer and the Shim.
- Loosen the Screw, and remove the Screw.
- Use the Puller and Puller to pull out the Link Arm a little bit, so that the Lower Support can be lowered.
- Unscrew and change the Distance Cylinder, including the O-ring.

- Screw
- Spacer
- Shim
- Screw
- Screw
- Puller
- Puller
- Link Arm
- Lower Support
- Distance Cylinder
- O-ring
Assemble
- Assemble a new O-ring , apply thread locker on the threads of the Distance Cylinder.Note: Avoid thread locker in the O-ring area.
- Tighten the cylinder on the Outer hexagonal head to a torque of 75±25Nm.
- Assemble in the reverse order.

- Distance Cylinder
- O-ring
- Outer hexagonal head
Link Arm Tool - Overhaul
| Equipment Status | Program Step |
| Special Equipment | Puller, TP No. 1573180 Puller, TP No. 1573181 |
Preparation
Risk of injuryBe careful when working near the shims.The shims in the LFU could be sharp.
- Remove the link arms, see Procedure Holder Tool - Remove.
Overhaul Link Arms
- Change the Ball Bearing.
- Change the Stud.
- Change the Retaining Ring.
Assemble
- Fit the link arms, see Procedure Holder Tool - Assemble.

- Retaining Ring
- Ball Bearing
- Stud
Holder Tool - Lubricate Linear Guide
| Equipment Status | Program Step step zero |
| Special Equipment | Grease gun: TP No. 3366407-0000 |
| Consumables | Grease: TP No. 344407-0000 |
- Use a Grease gun and lubricate the linear guides by adding grease to the Greasing Nipple.Note: The Lubrication Block are automatically lubricated with oil from the lubricating system.Note: Remove surplus lubrication.

- Grease gun
- Greasing Nipple
- Lubrication Block
Holder Tool - Remove
| Equipment Status | Program Step |
| Special Equipment | Puller TP No. 1573180 Puller TP No. 1573181 Wrench with extension |
Remove the Belts
- Loosen the belt tension by loosening the Screw.
- Remove the Screw and the Washer.
- Remove the Screw, the Washer, the Mounting Lug, and the Clamp.Note: Save the Mounting Lug and the Clamp for the assembly.
- Repeat Items Reference to Reference on the other side.
- Remove the Belt.

- Screw
- Screw
- Washer
- Screw
- Washer
- Mounting Lug
- Clamp
- Belt
Remove the Link Arms
Sharp edges.Keep hands clear from any sharp edges.Components with sharp edges can cause personal injuries.
Remove the Screw on the Link arm.- Use the Puller TP No. 1573180 and Puller TP No. 1573181, to remove the Link arm.
- Remove the Link arm.
- Repeat Items Reference to Reference on the other side.
- Remove the Spacer, see Procedure Pressing Unit - Check Spacer and Cylinder.

- Screw
- Link arm
- Puller TP No. 1573180
- Puller TP No. 1573181
- Spacer
Remove the Pressing Unit
- Remove the external tool, see Procedure External Tools - Remove.
- Remove the Screw from the Holder.
- Note the marking on the cooling water Hose and remove the hoses with nut and cone from the Block.
- Remove the cooling water Block.

- Screw
- Holder
- Hose
- Block
- Remove the Screw and pull out the Bar.
- Remove the Screw and the Beam.
- Remove the Screw, the Washer, and the Spring and pull out the Horizontal Cylinder.

- Screw
- Bar
- Screw
- Beam
- Screw
- Washer
- Spring
- Horizontal Cylinder
Remove the Holders
- Remove the Screw and the Washer.
- Remove the Holder.

- Holder
- Screw
- Washer
- Disconnect the grease hoses from the Carriage .
- Remove the Screw, the Washer, the Nut, and the Guide.

- Screw
- Carriage
- Screw
- Washer
- Nut
- Guide
Holder Tool - Overhaul
| Equipment Status | Program Step |
| Special Equipment | Puller, TP No. 1573180 Puller, TP No. 1573181 |
Preparation
- Remove the Screw, the Washer, and the Beam. See Procedure Holder Tool - Remove.

- Screw
- Washer
- Beam
Overhaul Link Arms
- Overhaul the link arms. See Procedure Link Arm Tool - Overhaul.
Overhaul Guides (Hot Channel Piston Version Without Cooling)
- Remove the Screw, the Washer, the Nut, and the Guide.
- If necessary, change the Guide and the Carriage.
- Remove the Plate from the Carriage.
- Remove the inner stop screws, and check that the channels are open for grease lubrication.Note: Be careful when sliding the new Carriage onto the Guide, and make sure not to lose any of the balls in the Carriage.
- Screw the grease Nipple into the inner holes of the carriages.
- Slide the Carriage onto the Guide with the mounting surface upwards and the Nipple downwards.Make sure that the Guide are in contact with the Guide dummy and that the grease Nipple are in the inner holes while sliding on the Carriage.Note: Make sure that the Nipple on the Carriage are pointing down when attached to the support.
- Assemble according to Procedure Holder Tool - Assemble.

- Screw
- Washer
- Nut
- Guide
- Carriage
- Guide dummy
- Nipple
- Plate
Overhaul Guides (Hot Channel Piston Version With Cooling)
- Remove the Screw, the Sleeve, the Washer, the Nut, and the Guide.
- If necessary, change the Guide and the Carriage.
- Remove the Plate from the Carriage.
- Remove the inner stop screws and check that the channels are open for grease lubrication.Note: Be careful when sliding the new Carriage onto the Guide and make sure not to lose any of the balls in the Carriage.
- Screw in the grease Nipple into the inner holes of the carriages.
- Slide the Carriage onto the Guide with the mounting surface upwards and the Nipple downwards.Make sure that the Guide are in contact with the Guide dummy and that the grease Nipple are in the inner holes while sliding on the Carriage.Note: Make sure that the Nipple on the Carriage are pointing down when attached to the support.
- Assemble according to Procedure Holder Tool - Assemble.

- Screw
- Sleeve
- Washer
- Nut
- Guide
- Carriage
- Guide dummy
- Nipple
- Plate
Holder Tool - Assemble
| Equipment Status | Program Step STEP ZERO |
| Special Equipment | Screw M8: TP No. 312105-0451 (2pc) Washer: TP No. 315125-0165 (2pc) |
| Consumables | Thread locker: TP No. 351532-0000 |
Assemble Holders
Note: The tool Holder are manufactured and marked in pairs. Do not mix them with other tool holders.- Make sure that the surface of the Carriage (see illustration below), on the Linear Guide, is pointing upwards.
- Assemble the Linear Guide. Tighten the Screw and Screw to 30 Nm.
- Connect the grease hoses for the lubricating of the Linear Guide.

- Linear Guide
- Carriage
- Screw
- Screw
- Assemble the Holder and Screw.Note: Do not tighten the Screw.

- Screw
- Holder
- Make sure the Screw are loose.
- Assemble the Screw M8 and Washer in the holes on the Holder. See illustration below.
- Tighten the Screw M8 so that the Carriage are pressed up against the Holder.Note: The Holder must touch each other, not the Carriage.
- Fix the Holder against each other, make sure that the Carriage are not touching each other. If necessary, press the Carriage apart.Note: The Screw have different heights of the head. The screws with a normal head are for the holes with a longer countersink.
- Tighten the Screw to 22 Nm.
- Remove the Screw M8 and Washer.

- Carriage
- Screw
- Holder
- Screw M8
- Washer
- Assemble the Horizontal Cylinder.
- Apply thread locker on the Screw. Assemble the Washer and the Spring. Tighten with 18 Nm.
- Assemble the Beam. Apply thread locker on the Screw.Tighten to 40 Nm.
- Fit both the Bars, see illustration. Tighten Screw with 296 Nm.
- Fit the Block and tighten the Screw.
- Assemble the external tool. See Procedure External Tools - Install.
- Assemble the scissors. See Procedure Pressing Unit - Check Spacer and Cylinder.

- Holder
- Screw
- Block
- Screw
- Washer
- Spring
- Bars
- Horizontal Cylinder
- Beam
- Screw
- Screw
Assemble Link Arms
- Fit the Link Arm. Tighten the Screw with 22 Nm.
- Assemble the Belt and set the tension. See Procedure Drive Tool - Set Belt Tension.
- Fit the mandrel wheel. See Procedure Mandrel Wheel - Assemble.

- Screw
- Belt
- Link Arm
Pressing Unit - Set Inductive Switch
| Equipment Status | Program Step |
Risk of damage to the equipment.Make sure that the distance
A is greater than 0 mm.If the
Inductive switch is set outside the
Flange it can collide with the
Spacer.
Remove the Screw and the Support from the cylinder (3).- Set the distance A to a maximum of 0.5 mm by adjusting the Inductive switch.
- Attach the Support and tighten the Screw.

A (mm) = 0 - 0.5
- Screw
- Support
- Cylinder
- Inductive switch
- Flange
- Spacer
Pressing Unit - Check Spacer and Cylinder
| Equipment Status | Program Step STEP ZERO |
| Special Equipment | Ruler Feeler gauge |
| Consumables | Thread locker: TP No. 351532-0000 |
- Remove the Screw and the Support.
- Check the Support for excessive wear and cracks. If necessary, change.
- Remove the Screw and the Washer.
- Lift out the Spacer.

- Screw
- Support
- Screw
- Washer
- Spacer
Note: The Ruler must rest against the Bushing of the Spacer.- Use a Ruler to check that the Spacer is not bent and make sure that the distance A is less than 0.1 mm.
- If necessary, change the Spacer.
- Check the Bushing for wear and damage. If necessary, change the Bushing.

A (mm) < 0.1
- Spacer
- Ruler
- Bushing
- Use a Ruler to make sure that the distance B is less than 0.1 mm.
- Change the Spacer if it is damaged.

B (mm) < 0.1
- Spacer
- Ruler
- Check the function of the Cylinder. If necessary, change the Cylinder. See Procedure Pressing Unit - Change Locking Cylinder on page Pressing Unit - Change Locking Cylinder.
- Check for oil leakage at the bottom of the beam, see illustration. If there is oil leakage, change the seals. See Procedure Pressing Unit - Change Seals and Bushings.
- Check with hand if the Distance is loose. If it is loose, tighten the Screw.

- Cylinder
- Distance
- Screw
- Put the Spacer back.Note: Apply thread locker on the Screw before assembling.
- Put the Washer back and tighten the Screw.
- Put the Support back and tighten the Screw.

- Screw
- Support
- Screw
- Washer
- Spacer
Centre the Scissor
- Loosen Screw.
- Use the remote control, see Procedure LFU Remote Control - Handle and activate Step 2 Locking Scissors.
- Tighten the Screw.
- Check the distance A with a feeler gauge. If the distance is not within the specified tolerance, it can be due to plastic in-between the tools. Clean according to the OM.
- Make sure that the Spacer moves easily.

A (mm) < 1.5
- Screw
- Spacer
Pressing Unit - Change Locking Cylinder
| Equipment Status | Air must be turn OFF. Program Step Program Step |
- Remove the air Hose and the Straight coupling from the Cylinder and mark the Hose for a proper assembly.Note: Note the markings on the Hose, A30W1304 (S1), A30W2304 (S2) at the non piston side (+ side), and A30W1305 (S1), A30W2305 (S2) at the piston side (- side), of the Cylinder.
- Remove the Nut and the Plate from the Cylinder.

1 - upper: A30W1304 (S1) & A30W2304 (S2)1 - lower: A30W1305 (S1) & A30W2305 (S2)
- Hose
- Straight coupling
- Cylinder
- Nut
- Plate
- Gently remove the Cylinder.
- Remove the Ring.

- Cylinder
- Ring
- Remove the lock Nut, the Connection and the Plate.
- Loosen the Screw on the new Cylinder as much as possible to make sure that the dampening is lowered to a minimum.
- Attach the lock Nut on the piston end of the new Cylinder, do not tighten.
- Attach the Connection to the new Cylinder and tighten.
- Attach the new Plate.
- Attach the new Ring.
- Put the two Straight coupling back on to the new Cylinder.

- Straight coupling
- Cylinder
- Ring
- Nut
- Connection
- Plate
- Screw
- Put back the Cylinder, non piston side first, on the pressing unit.
- Align the Cylinder and make sure that the two Straight coupling are horizontal.

- Straight coupling
- Cylinder
- Place the new Plate and tighten the end locking Nut.
- Place the air Hose to the Straight coupling.

- Hose
- Straight coupling
- Nut
- Plate
Pressing Unit - Change Seals and Bushings
| Equipment Status | Air must be turn OFF. Program Step STEP ZERO |
| Special Equipment | C-clamp |
| Consumables | Thread locker: TP No. 351532-0000 |
Burn hazard.Allow the LFU to cool down before starting any work on it.The external tools can be hot.
- Remove the external tools. See Procedure External Tools - Remove.
- Remove the Screw from the Holder, and then remove the cooling water Block.
- Note the marking on the cooling water hoses and remove the hoses with nut and cone from the Block.

- Screw
- Holder
- Block
- Pull the hoses through the Hole in the Cylinder.

- Hole
- Cylinder
- Remove the Screw, the Washer, and the Guide.
- Remove the Screw and the Support.
- Remove the Screw, the Washer, and the Spacer.
- Remove the Cylinder and take it to a work bench.

- Cylinder
- Screw
- Washer
- Guide
- Screw
- Support
- Screw
- Washer
- Spacer
- Remove the Screw, the Screw, and the Washer.
- Remove the Guide and the Spring.Note: The old Bearing bushing must be broken to be removed from the seat.
- Remove and change the Bearing bushing.

- Screw
- Screw
- Washer
- Guide
- Spring
- Bearing bushing
- Remove the Screw and the Distance.Note: Use a C-clamp to secure the spring force when removing the Retaining ring.
- Remove the Retaining ring, the Lid, the Spring, and the Piston.

- Screw
- Distance
- Retaining ring
- Lid
- Spring
- Piston
- Remove and change the Guide ring and the Seal ring.Note: Note the direction of the Seal ring.
- Assemble the Cylinder in the reverse order.Note: Apply thread locker on the Screw when assembling.
- Apply thread locker and tighten the Screw to a torque of 18 Nm.

- Cylinder
- Screw
- Screw
- Guide ring
- Seal ring
- Assemble the Cylinder, the Spacer, the Washer, and the Screw.
- Attach the Support to the Cylinder and tighten the Screw.Note: Tighten the Screw to a torque of 296 Nm.
- Attach the Guide, put the Washer in position and tighten the Screw.

- Cylinder
- Screw
- Washer
- Guide
- Screw
- Support
- Screw
- Washer
- Spacer
- Use the Screw to attach the cooling water Block to the Holder.
- Pass the cooling water hoses through the Hole in the Cylinder and put back the hoses, according to the notes from Item Reference, into the Block.
- Assemble the external tools. See Procedure External Tools - Install.
- Centre the scissor. See sub procedure Pressing Unit - Check Spacer and Cylinder on page Pressing Unit - Check Spacer and Cylinder.

- Screw
- Holder
- Block
- Hole
- Cylinder
Reference Stop - Change Sliding Strip
| Equipment Status | Program Step STEP ZERO |
| Consumables | Thread locker: TP No. 351532-0000 |
- Remove the LFU. See Procedure LFU - Move to Service Position.
- Remove the two Outer bearing half.
- Remove the Middle bearing half.
- Loosen the Stripper screw and remove the stripper.
- Remove the four mandrel wheel Fastening screw.

- Outer bearing half
- Middle bearing half
- Stripper screw
- Fastening screw
- Lift the mandrel wheel carefully approximately 20 mm and secure it in that position (to make sufficient space for removal of the reference stop).
- Remove the two reference stop Fastening screw.
- Remove the upper half of the Reference Stop.
- Remove the two sliding strip Fastening screw.
- Change the Sliding strip. Use thread locker on Fastening screw and tighten with a force of 3 Nm.
- Assemble in the reverse order.Note: Check that the Bronze washer and Steel washer are mounted in the correct order.

- Fastening screw
- Reference Stop
- Fastening screw
- Sliding strip
- Bronze washer
- Steel washer
Reference Stop - Change Spacers
| Equipment Status | Program Step STEP ZERO |
| Special Equipment | Rail, TP No. 915399-0002 Hydraulic hose: TP No. 3019750-0000 Hydraulic hose: TP No. 3019751-0000 |
To obtain the correct cavity for the respective opening type, use the correct type of spacer as specified in the table.| Opening | Spacer | D (mm) |
| Valid for: Mini Nallo C38 | 3614360-0000 | 45.75 |
| Valid for: Mini Eifel C38 | 3614360-0000 | 45.75 |
| Valid for: Midi Eifel C38 | 3614360-0000 | 45.75 |
| Valid for: Base Eifel C38 | 3614360-0000 | 45.75 |
| Valid for: All other openings | 2986073-0000 | 45.55 |

Spacer
- Move the LFU to service position. See Procedure LFU - Move to Service Position.
- To make enough space for removal of the Stop, carefully lift the mandrel wheel about 20 mm.
- Secure the mandrel wheel in the lifted position.
- Remove the Screw, the Washer (steel), and the Washer (bronze).
- Remove the upper-half of the Stop.
- Change the Spacer.
- Assemble in reverse order.Note: Do not tighten the Screw immediately. Tighten them first after centring the lower bearing half during the basic setup procedure.Note: Make sure that the Washer (steel) and the Washer (bronze) are mounted in the correct order. Use new Washer (bronze).

Reference Stop
- Screw
- Washer (steel)
- Washer (bronze)
- Stop
- Spacer
Hot Channel - Check
| Equipment Status | Program Step |
| Special Equipment | Scraper, TP no. 1573970 |
Note: The hot channel can be checked with the LFU in the machine.- Step the machine up to heating on the line to be checked, and wait until the machine has reached its working temperature.
Burn hazard.Allow the hot channel to cool down before starting any work on it.The hot channel and its connections can be hot.
Risk of damage to the equipment.Use the scraper TP No. 1573970 when cleaning the hot channel.If the hot channel is cleaned with steel tools, the surfaces can be damaged.
Remove all plastic residue with the scraper. Check for plastic leakage.- Check for any damage of the unit, in particular the Nozzle, the Contact surface, and the Protection plate.
- Check for leakage of hydraulic oil from the cylinder.
- Check for leakage of cooling water from cylinder and piston or cooling body.
- To check temperature and heating cartridges, see Hot Channel - Check Temperature and Heating Cartridges.

- Nozzle
- Contact surface
- Protection plate
Hot Channel - Set Needle
| Equipment Status | Program Step |
Set the distance A as following:- Disconnect the air hose from the cylinder.Note: The plastic inside the hot channel must be melted for the needle to move, when the needle tip is not in contact with the nozzle plate.
- Loosen the Nut.
- Adjust the Screw downwards until it is possible to insert a 3.5 mm 3.5 mm shim between the Screw and the Needle.
- Adjust the Screw upwards until the Piston reaches its bottom end (see pointer arrow).
- Tighten the Nut.
- Remove the 3.5 mm shim.
- Put the air hose back on the cylinder.

A (mm) =3.5 ±0.1
- Nut
- Screw
- 3.5 mm shim
- Needle
- Piston
Hot Channel - Basic Set of Plastic Dosing
| Equipment Status | Program Step STEP ZERO |
Burn hazard.Allow the hot channel to cool down before starting any work on it.The hot channel and its connections can be hot.
Foreword
The setting of the right amount of plastic is done in two steps: Basic Set and Final Set. See Hot Channel - Final Set of Plastic Dosing.Basic Set only gives a rough setting of the plastic amount and it must be followed by a Final Set.Basic Set of the Plastic Dose
- Loosen the Nut, and adjust the Stop Screw to the distance A, according to the table.
- Tighten the Nut.Note: If the Stop Screw should be moved inwards, do as follows:

- Piston
- Stop Screw
- Nut
Set Proximity Plate
- Loosen the Screw.
- Make sure that the Piston presses against the Stop Screw.
- Push and align the Plate toward the Screw and tighten the Screw.
- Adjust the Proximity Switch to the distance B.
- Measure the distance C between the Bracket and the tongue on the Plate.
- Calculate as follows: C - 1.8mm = D
- Adjust the Proximity Switch to the distance D ±0.2 mm.
Final SetPerform a final setting of the plastic dose. See Procedure Hot Channel - Final Set of Plastic Dosing.
B = 1.8 ±0.2 mm
- Piston
- Screw
- Plate
- Screw
- Stop Screw
- Proximity Switch
- Plate
- Proximity Switch
- Bracket
Hot Channel - Final Set of Plastic Dosing
| Equipment Status | Program Step |
- Produce 4 packages from each hot channel and measure the lid thickness according to OM Package Checks.
- Turn the service key to ON and then to off.
- The Button for Emptying Injection Cylinders for emptying the injection cylinders will appear in the Manoeuvre Window.

- Manoeuvre Window
- Button for Emptying Injection Cylinders
- When the Button for Emptying Injection Cylinders has been pressed, the button will turn to blue, and the Button for 1/0 the Emptying Sequence will appear.A help text
Empty InjCyl before dosing adjustment, will also be displayed. - Activate the 1/0 button, and step the machine up to PRODUCTION.The machine will feed two blanks into the conveyor, then empty the injection cylinders and make two lids. After this, the injection cylinders will not be refilled.The machine will automatically step down to TANK FILLING. Then it will be possible to adjust the dosing amount. See following instruction.

- Manoeuvre Window
- Button for Emptying Injection Cylinders
- Button for 1/0 the Emptying Sequence
- Open the doors and adjust the Stop Screw on the Injection Cylinder by loosening the Counter Nut.Note: By moving the stop screw outwards, the plastic dose will be increased.Note: It is possible that a small amount of oil will leak from the Counter Nut due to the release of tension. This is normal as the counter nut is also a sealing.
- Tighten the Counter Nut.
- Set the proximity switch. See Procedure Hot Channel - Basic Set of Plastic Dosing.
- Remove the packages from the mandrels.
- Close the doors and step the machine up to PRODUCTION.The machine is now in normal mode. If it is necessary to perform more adjustments, repeat from the beginning of this instruction.

- Injection Cylinder
- Counter Nut
- Stop Screw
Hot Channel - Remove
| Equipment Status | Air must be turn OFF. Program Step |
Burn hazard.Allow the hot channel to cool down before starting any work on it.The hot channel and its connections can be hot.
Risk of damage to the equipment.Be careful not to damage the surfaces on the hot channel.The surfaces on hot channel are easily damaged.
Preparation
- Disconnect the Deonized Water Quick Connections.

- Deonized Water Quick Connections
- Glycol Water Quick Connections
- Pull out the LFU. See Procedure LFU - Move to Service Position.
Remove
- Remove the Air Hoses.
- Remove the External tool. See Procedure 3.12.2-5.1 External Tools - Remove in the MM.
- Step up the machine to Program step : heating.

- Air Hoses
- External tool
The sealing on the hot channel are easily damaged.Be careful when removing the
Nozzle.
- Remove plastic remnants from the notches, then remove the Screw.
- Valid for Hot Channel Piston Version Without Cooling: Remove the Nozzle.
- Valid for Hot Channel Piston Version With Cooling: Carefully remove the Nozzle, by using two flat screwdrivers on both sides of the Nozzle.Note: Use the screwdrivers on the grooves (arrows), and with even force slowly remove the Nozzle.

Only Valid for Hot Channel Piston Version With Cooling.
- Screw
- Nozzle
- Remove the Seal.Note: Only valid for Hot Channel Piston Version Without Cooling.
- Remove the Seal.
- Disconnect the heated Plastic Hose.
- Make sure that the Hot Channel cools down to 50°C.
- Disconnect the Glycol Water Quick Connections, shown on page Reference.
- Disconnect the four Water Hoses.
- Remove the connections on the Sensors.Note: Make sure to note the order for the installation.
- Disconnect the Hydraulic Hose with the clamp.
- At the connection box, disconnect the Connections for the heating elements and the thermocouple.
- Remove the four Screw, and bring out the Hot Channel. Take care not to damage the Insulating Sheet.Note: The Needle is stuck in the cold plastic and will follow the Hot Channel out.

- Screw
- Nozzle
- Screw
- Seal
- Seal
- Plastic Hose
- Connections
- Hot Channel
- Insulating Sheet
- Needle
- Water Hoses
- Hydraulic Hose
Hot Channel - Change Temperature Switch
| Equipment Status | Power must be turn OFF.
|
Burn hazard.Allow the hot channel to cool down before starting any work on it.The hot channel and its connections can be hot.
Hazardous voltage.The main power supply disconnector must be switched off and secured with a lock before starting any work on the electrical equipment.Will shock, burn, or cause death.
Fault indicated by the hot channel temperature switch
A burned out hot channel element (by short-circuit) may result in the solid state relay burning out. If required, do the following:- Switch off or change the faulty hot channel element.
- Change the solid state relay, located in the Power supply unit.
| Side | Solid state relay |
| 1 | A30Q1027 and A30Q1028 |
| 2 | A30Q2027 and A30Q2028 |

- Power supply unit
Hot Channel - Change Needle
| Consumables | Loctite 8014 TP No. 344443-0907 Klüberpaste TP No. 344418-0319 |
Preparation
- Lift out the hot channel. See Hot Channel - Remove.
Hot Channel - Bench Disassemble
- Remove the Insulating Sheet.
- Tighten the Hot channel to a vice.
- Remove the Cover, the fourScrew, and the Spacer.
- Remove the Cooling body.

- Hot Channel
- Insulating Sheet
- Cover
- Screw
- Spacer
- Cooling body
Change Needle
Burn-hazard.Handle the hot channel and its parts with caution.The hot channel and its connections are hot.
- Remove the Screw.
- At the connection box, disconnect the electrical connections for the Heating hose.Note: The connections must be disconnected because the Heating hose is to be provided from HEATING when the machine is stepped up to HEATING.
- Connect the hot channel‘s Element units and the Thermocouple to the connection box.
- Make sure that the hot channel is placed so that it cannot damage anything during heating.Note: To avoid plastic leakage inside the hole for the bushing, place the Hot Channel with the bushing hole upwards.
- Activate the service key and step the machine up to heating.

- Screw
- Flange
- Needle
- Bushing
- Plastic ring
- Heating hose
- Element units
- Thermocouple
- When the plastic is warm enough, remove the Needle.
- Deactivate the service key (heating will be lost).
- Remove the Flange.
- Remove the Bushing.
- Remove the Plastic ring, and discard.
- Remove any left over plastic residue, from where the Bushing was placed.

- Screw
- Flange
- Needle
- Bushing
- Plastic ring
Reassemble
Note: The Bushing and the Needle have matched tolerances and must always be changed together.Burn hazard.Handle the hot channel and its parts with caution.The hot channel and its connections are hot.
- Make sure that all parts of the hot channel are clean and free from plastic residue.
- Apply a layer of Loctite 8014: TP No. 344443-0907 on the Bushing.
- Install a new Plastic ring on the Bushing.Note: To avoid plastic leakage inside the hole for the bushing, place the Hot Channel with the bushing hole upwards.
- Heat up until the plastic inside the hot channel start to melt.
- Install the Bushing.
- Install the Flange.
- Lubricate the Screw with Klüberpaste: TP No. 344418-0319.Note: If Klüberpaste is not applied to the screws there is a large risk that the threads will seize causing irreparable damage to the hot channel.
- Tighten the Screw to a torque between 3Nm and 3.5Nm.
- Lubricate the contact surface A of the Needle with Loctite 8014: TP No. 344443-0907.
- Fit the Needle when the plastic is warm enough and set the distance B (35 mm).Note: B is only a distance to make clearance for later assembly of the Nozzle, see .
B = 35 mm
- Screw
- Flange
- Needle
- Bushing
- Plastic ring
Hot Channel - Bench Assemble
- Tighten the Hot channel to a vice.
- Apply Klüberpaste: TP No. 344418-0319 on the Screw.Note: If Klüberpaste is not applied to the screws there is a large risk that the threads will seize causing irreparable damage to the hot channel.
- Assemble the Injection cylinder, the Spacers, with the Screw, and tighten to a torque between 30Nm and 100Nm.
- Install the Cover.
- Install the Hot channel in the machine. See Hot Channel - Install.

- Hot channel
- Screw
- Injection cylinder
- Cover
Hot Channel - Change Needle
| Equipment Status | Program Step HEATING |
| Consumables | Anti-seize Loctite 8014: TP No. 344443-0907 |
Preparation
- If the inner hot channel’s needle must be changed, pull out the LFU. See Procedure LFU - Move to Service Position.The outer hot channel’s needle can be changed without pulling out the LFU from the machine.
- Activate the service key and step the machine up to heating.
Change Needle
Hazardous noise.Wear hearing protection before disconnecting the
Air Hose.The air pressure is permanently on in the
Air Hose.
- Remove the Air Hose that is connected to the side where the Needle will be changed. Plug the air hose.

- Air Hose
- Remove the Attachment pipe.
- Loosen the Counter nut and turn the Screw downwards so that the pre-tension on the Needle is lost.
- Remove the Screws and bring out the Cylinder.
Burn hazard.Allow the hot channel to cool down before touching the
Needle.The hot channel and its connections can be hot.
Remove the Needle.
Reassemble
- Lubricate the contact surface A of the Needle with Loctite 8014: TP No. 344443-0907, and fit the Needle.
- Assemble the Cylinder, and tighten the Screws.
- Assemble the Attachment pipe and the air hose.
- Set the Needle. See Procedure Hot Channel - Set Needle.
- Deactivate the service key (heating will be lost).
- Fit the LFU. See Procedure LFU - Install from Service Position.

- Attachment pipe
- Cylinder
- Screws
- Needle
- Screw
- Counter nut
Hot Channel - Overhaul Injection Cylinder
| Equipment Status | Program Step |
| Special Equipment | Sleeve TP no. 2888709 |
| Consumables | Klüberpaste TP No. 344418-0319 |
Remove
Burn hazard.Allow the hot channel to cool down before starting any work on it.The hot channel and its connections can be hot.
- Lift out the hot channel. See Hot Channel - Remove.
- Remove the Insulating Sheet.
- Tighten the Hot channel to a vice.
- Remove the Cover, the four Screw, and the Spacer.

- Hot Channel
- Insulating Sheet
- Cover
- Screw
- Spacer
- Remove the Screw to remove the Sheet.
- Remove the Screws, to remove the Sensor Plate with the Sensor.

- Screw
- Sheet
- Screws
- Sensor Plate
- Sensor
Overhaul Injection Cylinder
- Remove the wear Wear Ring, the Rod Seal, and the Scraper.
- Fit the Wear Ring and Rod Seal.
- Fit the Scraper. Use the Sleeve according to the illustration to do this. It is recommended that you use a press to do this.Note: See illustration for direction of the Rod Seal and the Scraper.

- Hot channel
- Wear Ring
- Rod Seal
- Scraper
- Sleeve
Hot Channel - Bench Assemble- Tighten the Hot channel to a vice.
- Apply Klüberpaste: TP No. 344418-0319 on the Screw.Note: If Klüberpaste is not applied to the screws there is a large risk that the threads will seize causing irreparable damage to the hot channel.
- Assemble the Injection cylinder, the Spacer, with the Screw, and tighten to a torque between 30Nm and 100Nm.
- Install the Cover.
- Assemble the Sensor Plate and the Sensor with the Screws.
- Assemble the Screw with the Sheet.
- Install the Hot channel in the machine. See Hot Channel - Install.

- Hot channel
- Cover
- Screw
- Spacer
- Screw
- Sheet
- Screws
- Sensor Plate
- Sensor
- Injection cylinder
Hot Channel - Install
| Equipment Status | Program Step STEP ZERO |
| Consumables | Klüberpaste UH1 96-402: TP No. 344418-0319 Anti-seize Loctite 8014: TP No. 344443-0907 Seal: TP No. 2745292-0000 |
Assemble
- Clean the Hole for the needle, the area around the Needle cylinder, and the top surface of the Support where the hot channel will be installed.
- Install the Pin and the Insulating Sheet on the Support.Note: Make sure that the Insulating Sheet is not damaged before assembling.
- Place the hot channel temporary on the Support to be able to connect the water hoses.

- Hole
- Needle cylinder
- Support
- Pin
- Insulating Sheet
Install the water hoses according to the illustration. The illustration is showing S1. The configuration for S2 is mirrored in relation to the illustration.- Valid for: Equipment with Hot Channel Piston without coolingInstall water hoses on the Injection Cylinder Piston according to the filled lines in the illustration.
- Valid for: Equipment with Hot Channel Piston with coolingInstall water hoses on the Cooling body according to the dotted lines in the illustration.
- Install the Hose, the Hose, and the Hose on the Cooling body.

- Hose
- Hose
- Hose
- Cooling body
- Apply Klüberpaste: TP No. 344418-0319 on the Screw.Note: If Klüberpaste is not applied to the screws there is a large risk that the threads will seize causing irreparable damage to the hot channel.
- Tighten the Screw to 11 Nm.
- Fit the Seal, the Seal ring, and the Nozzle.Note: The seal (9) is only valid for Piston versions without cooling.Note: Always change the Seal when the Nozzle has been removed.
- Apply Klüberpaste: TP No. 344418-0319 on the Screw.Note: If Klüberpaste is not applied to the screws there is a large risk that the threads will seize causing irreparable damage to the hot channel.
- Tighten the Screw to 11 Nm.Note: After the first warm up to heating, re-tighten the Screw.

- Insulating Sheet
- Screw
- Nozzle
- Screw
- Seal
- Seal ring
- Heating Hose
- Hot Channel
- Water hoses
- Connect the Water hoses.
- Fit the External tool. See Procedure External Tools - Install.
- At the connection box, connect the Connections for the heating elements, and the thermocouple.
- Fit the connections for the Sensors in the same position as before the disconnection.
- Connect the Hydraulic hose with the clamp.
- Connect the Deonized water quick connections and the Glycol water quick connections.
- Apply Loctite 8014: TP No. 344443-0907 on the connection of the Heating Hose.
- Install the Heating Hose. See Accumulator - Change Heating Hose.

- Heating Hose
- Connections
- Water hoses
- Hydraulic hose
Note: Make sure that the Air Hose is plugged and disconnected.- Check for cooling water level alarm on the TPOP. If the cooling water level is too low, fill the expansion vessel according to procedure Cooling Water System - Fill or Bleed Glycol System and test run the cooling system for leaks.
- Reconnect the Air Hose.

- Air Hose
- Set the pretension of the Needle by adjusting the Needle cylinder. See Procedure Hot Channel - Set Needle.
- Connect the Air hose.
- Bleed injection cylinder. See Procedure Hydraulic System LFU - Bleed.
- Wipe up the waste water and oil from the LFU.
- Fit the LFU. See Procedure LFU - Install from Service Position.

- Needle cylinder
- Air hose
- External tool
- Needle
- Check the distance between the hot channel and the External tool. See Procedure LFU - Basic Set.
- Retighten the Screw to 11Nm.

- Screw
Hot Channel - Check Temperature and Heating Cartridges
| Equipment Status | Program Step Step heating |
- Start by checking the 1:1 hot channel.
- Check on the TPOP that the Temperature is set according to Temperatures LFU - Record in the MM.

- Temperature
- Note the Value.

- Value
- Repeat items Reference to Reference. For the 1:2, 2:1, and 2:2 hot channels.
- If any of the values differ more than 5% between the different stations on the same side, continue as follows:
- Step the machine down to step zero.
Hazardous voltage.The main power supply disconnector must be switched off and secured with a lock before starting any work on the electrical equipment.Will shock, burn, or cause death.
Make sure that the Connection and the Connection are correctly installed in the Heating element and that no problem has occurred as a result of bad connections.- Disconnect the Connection and the Connection from the Connection box and measure the electrical resistance. The resistance of the heating element should be 170 ±10ohm.
- If the connections are damaged, change them.
- If the resistance is not within the desired value, change the Heating element.
- Connect the Connection and the Connection.

- Connection
- Connection
- Heating element
Hot Channel - Overhaul Cooling Body
| Equipment Status | Air must be turn OFF.
|
| Special Equipment | Vice |
| Consumables | Loctite 8014 TP No. 344443-0907 Klüberpaste TP No. 344418-0319 |
Burn hazard.Use caution when working near the hot channels.The hot channels can be hot.
- Lift out the hot channel. See Hot Channel - Remove.
- Remove the Insulating Sheet .
- Tighten the Hot channel to a vice.
- Remove the Cover, the four Screw, and the Spacer.
- Remove the Cooling body.

- Hot Channel
- Insulating Sheet
- Cover
- Screw
- Spacer
- Cooling body
- Remove the Screw.
- Remove the Lid.
- Change the O-rings.
- Apply a thin layer of Loctite 8014: TP No. 344443-0907 to the narrow diameter of the Cylinder.Note: Check that the interior of the Cooling body is free from dirt.
- Reassemble the Cooling body onto the Cylinder.Note: Make sure not to damage the O-rings.

- Cooling body
- Screw
- Lid
- O-rings
- Cylinder
Hot Channel - Bench Assemble- Tighten the Hot channel to a vice.
- Apply Klüberpaste: TP No. 344418-0319 on the Screw.Note: If Klüberpaste is not applied to the screws there is a large risk that the threads will seize causing irreparable damage to the hot channel.
- Assemble the Injection cylinder, the Spacers, with the Screw, and tighten to a torque between 30Nm and 100Nm.
- Install the Cover.
- Install the hot channel in the machine. See Hot Channel - Install.

- Hot channel
- Screw
- Injection cylinder
- Cover
Hot Channel - Change Hot Channel Cylinder and Piston
| Equipment Status | Program Step Step zero |
| Special Equipment | Vice |
| Consumables | Klüberpaste UH1 96-402: TP No. 344418-0319 Anti-seize Loctite 8014: TP No. 344443-0907 |
Preparation
- Lift out the hot channel. See Hot Channel - Remove.
Hot Channel - Bench Disassembly
- Remove the Insulating Sheet.
- Put the Hot channel in a vice.
- Remove the Cover, the four Screw, and the Spacer.
- Remove the Cooling body.

- Hot channel
- Insulating Sheet
- Cover
- Screw
- Spacer
- Cooling body
If the hot channel has been cooled down, perform the following steps to make the cleaning of the hot channel easier:Note: The following steps are only valid if the hot channel has been cooled down.- At the connection box, disconnect the electrical connections for the Heating Hose.Note: The connections must be disconnected because the Heating Hose is to be prevented from heating when the machine is stepped up to HEATING.
- Connect the Element Units and the Thermocouple for the hot channel to the connection box.
- Make sure that the hot channel is placed so that it cannot damage anything during HEATING.
- Activate the service key, and step the machine up to HEATING.

- Heating Hose
- Element Units
- Thermocouple
Hot Channel DisassemblyNote: To avoid flooding of melted plastic, make sure that the temperature of the plastic is below 90°C (not liquid).- Remove the Screw.
- Remove the Flange.
- Remove all plastic leakage.
- Remove the Cylinder.
- Remove the Plastic ring.

- Cooling body
- Screw
- Flange
- Piston
- Cylinder
- Plastic ring
Risk of damage to the equipment.Take care to not damage the
Piston.The
Piston can slide out of the
Cylinder and become damaged.
- Remove the Piston from the Cylinder.Note: The piston (4) and the cylinder (5) have matching tolerances and must always be changed together.

- Piston
- Cylinder
Cleaning and Assembly
- Make sure the greyed out areas of the hot channel are clean and free from plastic residue that might prevent the parts from being installed correctly.
- Make sure all Thread in the hot channel are clean.

- Thread
- Apply Loctite 8014: TP No. 344443-0907 on a new Plastic ring, and install it in the groove in the Cylinder.

- Cylinder
- Plastic ring
- Install the Cylinder in the hot channel.Note: Make sure that the Cylinder reaches the bottom of the hot channel and is correctly mounted, with the Plastic ring properly attached. If this is not done, or if the ring is missing, the screws will break.

- Cylinder
- Plastic ring
Compress Plastic RingNote: The instructions below must be followed, or the screws will break after running the machine for a short time.- Make sure that the threads in the hot channel are clean.
- Make sure that the Flange is free from plastic residue.
- Place the Flange on the hot channel. Make sure that the recessed side of the Flange is facing the hot channel.

- Flange
Note: The instructions below must be followed, or the screws will break after running the machine for a short time.- Use new Screw. Lubricate the Screw with Klüberpaste: TP No. 344418-0319.Note: If Klüberpaste is not applied to the screws there is a large risk that the threads will seize causing irreparable damage to the hot channel.
- Tighten the screws crosswise by hand.
- Tighten the Screw crosswise, in small steps, to 4 Nm to compress the Plastic ring.
- Unscrew the Screw, and remove them completely.Note: Make sure that the Cylinder does not move. This may cause the Plastic ring to move from its position.

- Screw
- Cylinder
- Plastic ring
Tightening Sequence- For the machine to work properly without breakdowns, the Flange must be parallel to the Hot channel when tightening the Screw. A must be equal to B, see the following illustration.

- Flange
- Hot channel
Note: The instructions below must be followed, or the screws will break after running the machine for a short time.- Press the Flange against the hot channel with your fingers to make the Flange parallel to the hot channel. Simultaneously install the screws, and turn them with your fingers until they make contact with the Flange.
- Use a marker pen to write numbers on the hot channel. See the following illustration.
In the following tightening sequence, the screws must rotate in the final step, when tightening to 11 Nm. If the screws do not rotate when tightening to 11 Nm, restart the process, see item Reference.- Tighten the screws to 4 Nm in the following pattern: 12, 6, 3, 9.
- Tighten the screws to 8 Nm in the following pattern: 6, 12, 9, 3.
- Tighten the screw to 11 Nm in the following pattern: 12, 6, 3, 9.
Risk of damage to the equipment.Take care to not damage the
Piston.The
Piston can slide out of the
Cylinder and become damaged.
- Make sure that there is no dirt or dust on the surface of the Piston.
- Lubricate the Piston with Loctite 8014: TP No. 344443-0907.

- Piston
- Install the Piston in the Cylinder so that the hole in the Piston is facing the hot channel.Note: The Piston and the Cylinder have matching tolerances and must always be changed together.

- Piston
- Cylinder
- Apply a thin layer of Loctite 8014: TP No. 344443-0907, to the narrow diameter on the Cylinder.
- Install the Cooling body.Note: Check that the interior of the Cooling body is free from dirt.Note: Make sure not to damage the o-rings in the Cooling body.

- Cooling body
- Cylinder
Hot Channel - Bench Assemble
- Put the Hot channel in a vice.
- Apply Klüberpaste: TP No. 344418-0319, on the Screw.Note: If Klüberpaste is not applied to the screws there is a large risk that the threads will seize causing irreparable damage to the hot channel.
- Assemble the Injection cylinder, the Spacers, and the Screw, and tighten to a torque between 30Nm and 100Nm.
- Install the Cover.
- Install the hot channel in the machine. See Hot Channel - Install.

- Hot channel
- Screw
- Injection cylinder
- Cover
Guide Hot Channel - Set Inductive Switch
| Equipment Status | Program Step |
Risk of damage to the equipment.Make sure the distance
A is correctly set.If the
Inductive switch is set too close to the
Holder it can collide with the
Holder.
Note: The maximum operating distance of the Inductive switch is 2 mm.- Set the distance A by adjusting the Inductive switch.

A (mm) = 1 ± 0.2
- Inductive switch
- Holder
Guide Hot Channel - Change Distance Cylinders
| Equipment Status | Program Step AIR ON |
| Special Equipment | Drift, TP No. 2902937 Seal Ring Disassemble Tool Template, TP No. 2799379 |
| Consumables | Thread locker: TP No. 351532-0000 |
Handle Remote Control
Risk of injuryBe careful when working near the shims.The shims in the LFU could be sharp.
Risk of Personal Injury.The service key must only be used, and the valves must only be forced by trained service personal. Otherwise is there a risk for personal injuries due to lack of competence.
Risk of crushing and cutting.Enclose the area around the LFU and make sure that no unauthorised personnel can come in contact with the LFU.The movement in the LFU can cause injuries.
Instruction regarding handle of the remote control and recharging accumulator, see LFU Remote Control - Handle.- Make sure that the mandrel wheel and external tools do not collide with each other.
- Insert the service key and activate step 1 (Hydraulic high Pressure).
- Activate step 2 (Lock), close tools with the recharge accumulator valve, and activate step 3 (Horizontal force).
- Fit the Template, TP No 2799379, and step down to step 1.The external tools will now stop against the Holder, this operation makes it further on possible to lower the Support and Support.Note: If the hydraulic pressure drops to 0 bars in the same way as if an emergency stop button is activated, or the hydraulic oil temperature reaches its alarm level, or power failure on the machine etc. the external tools will open without warning.
- Shut down the hydraulic unit, by stepping down from step 1 (Hydraulic high Pressure) and leave the “Service functions ” window.
- Remove the belt cover. See Motor Unit - Remove Cover.

- Support
- Support
- Holder
- Template, TP No 2799379
- Locked Position
- Remove the Screw and the Shim.Note: The removal of the Screw and the Shim must be done at both sides, otherwise it will not be possible to lower the Support and Support.
- Remove the Hydraulic Hose.
- Lower the Support and Support with aid of an aluminium crow bar.
- Remove the Screw with the washer.
- Pull out the Distance Cylinder.

- Shim
- Screw
- Hydraulic Hose
- Screw
- Distance Cylinder
- Support
- Support
Reassemble
- Assemble the Distance Cylinder.
- Apply thread locker on the Screw and fit the Screw with washer.
- Disconnect the electrical connection for the Distance cylinder valve (S1/A30K1228, S2/A30K2228).Note: This will prevent the Distance Cylinder to be activated during the reassembling!
- Insert the service key and choose “Service S1,(S2) ”, see Procedure LFU Remote Control - Handle. The hydraulic unit will now start on low pressure.
- Move up the supports with the Recharging accumulator valve (S1/A30K1223, S2/A30K2223).

- Screw
- Distance Cylinder
- Distance cylinder valve (S1/A30K1228, S2/A30K2228)
- Recharging accumulator valve (S1/A30K1223, S2/A30K2223)
- Assemble the Screw and Shim, on both sides.
- Fit and tighten the Hydraulic Hose.
- Connect the electrical connection, on the Distance cylinder valve (S1/A30K1228, S2/A30K2228).

- Shim
- Hydraulic Hose
- Screw
- Distance cylinder valve (S1/A30K1228, S2/A30K2228)
Guide Hot Channel - Change Vertical Cylinder
| Equipment Status | Program Step step zero |
| Special Equipment | Clamp Crowbar or similar item |
| Consumables | Grease: TP No. 344407-0000 Thread locker: TP No. 351532-0000 |
Risk of crushing.Make sure that the
Scissor is properly locked.There are moving parts in the machine.
- Use the remote control. See Procedure LFU Remote Control - Handle and activate Step 2 Locking Scissors.
- Fit a screw through the Hole in the Scissor and tighten with a nut to lock the Scissor.

- Scissor
- Hole
- Disconnect the hydraulic extension hoses.Note: Place a vessel under the LFU to collect the residual oil.Note: Clean the Vertical cylinder and the surrounding area from dirt and oil and maintain the area clean throughout the complete change.
- Disconnect the four hydraulic hoses from the Vertical cylinder. Note: Clean the hose connections from dirt and oil and maintain them clean throughout the complete procedure.
- Remove the Screw and the Screw.
- Remove the Screw, the Washer and the Ring.
- Remove the Plate.

- Vertical cylinder
- Screw
- Screw
- Screw
- Washer
- Ring
- Plate
- Remove the Screw.
- Fasten a strap around the Holder and lift it upwards to get space for the removal of the Vertical cylinder.Note: If the Vertical cylinder is difficult to remove, remove the Test point screw of the Vertical cylinder to release some pressure.
- Remove the Vertical cylinder.Note: Note the direction of the Vertical cylinder before removing it. It is important that the new Vertical cylinder is mounted in the same direction as the old.Note: Place a clamp around the Vertical cylinder to get a grip for a crowbar or similar.
- Remove and change the Back up ring and the O-ring.

- Vertical cylinder
- Screw
- Holder
- Test point screw
- Back up ring
- O-ring
Assemble
- Assemble the new Vertical cylinder. Note the direction of the Vertical cylinder.
- Assemble the Holder and the Screw. Apply grease on the screws and tighten them crosswise to a final torque of 122Nm.
- Apply thread locker on the Screw. Assemble the Plate, Ring, Washer, and Screw. Tighten to a torque of 22Nm.Note: After tightening of the Screw, check that the Plate can float. If this not is possible, check the height on the Ring.
- Fill the Hole with grease.
- Apply thread locker on the Screw and the Screw and assemble them.

- Vertical cylinder
- Screw
- Screw
- Screw
- Washer
- Ring
- Plate
- Screw
- Holder
- Hole
Guide Hot Channel - Overhaul
| Equipment Status | Program Step |
| Special Equipment | Lever Press |
| Consumables | Thread locker: TP No. 351532-0000 Thread sealant: TP No. 344447-0050 |
Risk of injuryBe careful when working near the shims.The shims in the LFU could be sharp.
Foreword
The overhaul instruction for the hot channel guide, is separated in the following instructions:- Overhaul Air Cylinder
- Overhaul Support
- Change Vertical Cylinder
- LFU - Basic Set
It is advisable to do them in this order, to get the right flow in the work.
Overhaul Air Cylinder
- Unload the air Cylinder, see Procedure Hot Channel - Set Needle on page Hot Channel - Set Needle.
- Remove the Attachment Pipe.
- Remove the air Cylinder.
- Take out the Piston and the Spring.
- Remove the Scraper and the Sealing.Note: Take care of the Washer and the damper (6).
- Fit the new Scraper and Sealing. Use the Sleeve to install the scraper. It is recommended that you use a lever press.Note: See the illustration, for the right directions.
- Assemble the Damper and the Washer.
- Assemble the Spring and the Piston.
Final assembly
Note: Final assembly, should be done after that the overhaul is performed on the hot channel.- Fit the air Cylinder in its origin place, assemble and tighten the screws.
- Apply thread sealant on the Attachment Pipe, fit and tighten it.
- Set the pretension on the needle. See Procedure Hot Channel - Set Needle on page Hot Channel - Set Needle.

- Piston
- Scraper
- Sealing
- Spring
- Washer
- Damper
- Cylinder
- Attachment Pipe
- Sleeve
Overhaul Support
- Remove the hot channels. See Procedure Hot Channel - Remove on page Hot Channel - Remove.
- Disconnect the Water hoses.
- Remove the Screw, the Spacer, and the Shim.Note: Do not mix the Shim with the other side.
- Remove the Screws on the Plate.
- Remove the Support.
- Remove the Screw including washer, and lift out the Distance cylinder.
- Remove the Grub screw, and tap out the four Bushing.

- Support
- Shim
- Screw
- Distance cylinder
- Water hoses
- Spacer
- Screw
- Bushing
- Grub screw
- Screws
- Plate
Assemble
- Tap gently in four new Bushing, in the Support.Note: On one off the bushings holes, in the Support, so is there a Lubricating hole which shall be aligned towards the lubricating hole in the Bushing.Note: Do not mistaken, and align the lubricating hole in the Bushing, towards the Hole for the Grub screw.
- Apply thread locker on the Grub screw and tighten them.Note: Do not tighten the Grub screw to hard, risk for deformation on the Bushing.

- Support
- Bushing
- Lubricating hole
- Grub screw
- Hole
- Assemble new Distance cylinder in the Support.
- Apply thread locker on the Screw, fit the washer and tighten.
- Assemble the Support on the Hot channel guide.Note: Before this is done, change the vertical cylinder, see .
- Apply thread locker on the Screws, fit and tighten.
- Fit the hot channel to the Support. See Procedure Hot Channel - Install on page Hot Channel - Install.
- Prepare the Screw, the Spacer, and the Shim, to be ready to use when the Support are assembled.

- Support
- Shim
- Screw
- Distance cylinder
- Water Hoses
- Spacer
- Screw
- Hot channel guide
- Screws
- Plate
- Support
Change Vertical Cylinder
Change the vertical cylinder. See Procedure Guide Hot Channel - Change Vertical Cylinder.Perform a basic set. See Procedure LFU - Basic Set on page LFU - Basic Set.Guide Hot Channel - Change Distance Cylinders
| Equipment Status | Program Step AIR ON |
| Special Equipment | Drift, TP No. 2902937 Seal Ring Disassemble Tool Locking Loop, TP No. 3674453-0000 |
Handle Remote Control
Risk of injuryBe careful when working near the shims.The shims in the LFU could be sharp.
Risk of Personal Injury.The service key must only be used, and the valves must only be forced by trained service personal. Otherwise is there a risk for personal injuries due to lack of competence.
Risk of crushing and cutting.Enclose the area around the LFU and make sure that no unauthorised personnel can come in contact with the LFU.The movement in the LFU can cause injuries.
Instruction regarding handle of the remote control and recharging accumulator, see LFU Remote Control - Handle.- Make sure that the mandrel wheel and external tools do not collide with each other.
- Insert the service key and activate step 1 (Hydraulic high Pressure).
- Activate step 2 (Lock), close tools with the recharge accumulator valve.
- Install the Locking Loop in the Hole in the Scissor and lock it with the Pin.
- Step down to step ZERO.
- Leave the “Service functions ” window.
- Remove the belt cover. See Motor Unit - Remove Cover.

- Locking Loop
- Hole
- Scissor
- Pin
- Remove the Screw and the Shim.Note: The removal of the Screw and the Shim must be done at both sides, otherwise it will not be possible to lower the Support and Support.Note: Do not mix the shims between the sides.
- Remove the Hydraulic Hose.
- Lower the Support and Support with aid of an aluminium crow bar.
- Remove the Screw with the washer.
- Pull out the Distance Cylinder.

- Shim
- Screw
- Hydraulic Hose
- Screw
- Distance Cylinder
- Support
- Support
Reassemble
- Assemble the Distance Cylinder.
- Fit the Screw with a washer.
- Disconnect the electrical connection for the Distance cylinder valve (S1/A30K1228, S2/A30K2228).Note: This will prevent the Distance Cylinder to be activated during the reassembling!
- Insert the service key and choose “Service S1,(S2) ”, see Procedure LFU Remote Control - Handle. The hydraulic unit will now start on low pressure.
- Move up the supports with the Recharging accumulator valve (S1/A30K1223, S2/A30K2223).

- Screw
- Distance Cylinder
- Distance cylinder valve (S1/A30K1228, S2/A30K2228)
- Recharging accumulator valve (S1/A30K1223, S2/A30K2223)
- Assemble the Screw and Shim, on both sides.
- Fit and tighten the Hydraulic Hose.
- Connect the electrical connection, on the Distance cylinder valve (S1/A30K1228, S2/A30K2228).
- Remove the locking loop.

- Shim
- Hydraulic Hose
- Screw
- Distance cylinder valve (S1/A30K1228, S2/A30K2228)
Guide Hot Channel - Change Vertical Cylinder
| Equipment Status | Program Step step zero |
| Special Equipment | Clamp Crowbar or similar item Locking Loop, TP No. 3674453-0000 |
| Consumables | Grease: TP No. 344407-0000 Thread locker: TP No. 351532-0000 |
Risk of crushing.Make sure that the
Scissor is properly locked.There are moving parts in the machine.
- Use the remote control. See Procedure LFU Remote Control - Handle, and activate Step 2 Locking Scissors.
- Install the Locking Loop in the Hole in the Scissor and lock it with the Pin.

- Locking Loop
- Hole
- Scissor
- Pin
- Disconnect the hydraulic extension hoses.Note: Place a vessel under the LFU to collect the residual oil.Note: Clean the Vertical cylinder and the surrounding area from dirt and oil.
- Disconnect the four hydraulic hoses from the Vertical cylinder. Note: Clean the hose connections from dirt and oil.
- Remove the Screw and the Screw.
- Remove the Screw, the Washer and the Ring.
- Remove the Plate.

- Vertical cylinder
- Screw
- Screw
- Screw
- Washer
- Ring
- Plate
- Remove the Screw.
- Fasten a strap around the Holder and lift it upwards to get space for the removal of the Vertical cylinder.Note: If the Vertical cylinder is difficult to remove, remove the Test point screw of the Vertical cylinder to release some pressure.
- Remove the Vertical cylinder.Note: Note the direction of the Vertical cylinder before removing it. It is important that the new Vertical cylinder is mounted in the same direction as the old.Note: Place a clamp around the Vertical cylinder to get a grip for a crowbar or similar.
- Remove and change the Back up ring and the O-ring.

- Vertical cylinder
- Screw
- Holder
- Test point screw
- Back up ring
- O-ring
Assemble
- Assemble the new Vertical cylinder. Note the direction of the Vertical cylinder.
- Assemble the Holder and the Screw. Apply grease on the screws and tighten them crosswise to a final torque of 122Nm.
- Apply thread locker on the Screw. Assemble the Plate, Ring, Washer, and Screw. Tighten to a torque of 22Nm.Note: After tightening of the Screw, check that the Plate can float. If this not is possible, check the height on the Ring.
- Fill the Hole with grease.
- Apply thread locker on the Screw and the Screw and assemble them.
- Remove the locking loop.

- Vertical cylinder
- Screw
- Screw
- Screw
- Washer
- Ring
- Plate
- Screw
- Holder
- Hole
Description
The extruder motor runs at two different speeds determined by the level of plastic in the plastic accumulator. The level is supervised by the Inductive sensor (upper) and the Inductive sensor (lower).When the LFU is running continuously the extruder motor is supposed to run mainly in low speed mode, occasionally changing to high speed mode (every second or third injection).Problems with the extruder motor will be indicated by a common alarm, displayed as “F/C FEEDER MOTOR OVERLOAD” on the TPOP panel. This alarm can be the result of mechanical and/or electrical overload, as well as if the extruder motor has been running continuously at high speed for more than 30 seconds. The latter is to indicate a blocked or limited granulate flow into the extruder or a leakage of plastic after the extruder.If the "low" speed of the extruder is set too high, the extruder will not switch to "high" speed as intended. Then there is a risk that the alarm "F/C FEEDER MOTOR OVERLOAD" will not be set if a heated hose breaks.
- Plastic accumulator
- Inductive sensor (upper)
- Inductive sensor (lower)
If the Plastic accumulator hits the mechanical stop when it is filled, and the extruder does not stop in time, a high pressure peak can be created in the heated hose. The pictures below show the three different stages of the Plastic accumulator function.(A) The Plastic accumulator is full. The Inductive sensor (upper) and Inductive sensor (lower) are both activated and stops the extruder motor. No plastic is fed to the plastic accumulator.(B) One Inductive sensor (upper) (the upper sensor), is activated and sets the low speed to the extruder motor. Plastic is continuously fed to the plastic accumulator.(C) The Plastic accumulator is empty. None of the sensors are activated. This sets high speed to the extruder motor. Plastic is fed up to the Plastic accumulator. 
- Plastic accumulator
- Inductive sensor (upper)
- Inductive sensor (lower)
- Sheet
- Piston
Transfer Unit - Check
| Equipment Status | Power must be turn OFF. Program Step Step Zero |
Hazardous voltage.The main power supply disconnector must be switched off and secured with a lock before starting any work on the electrical equipment. Will shock, burn or cause death.
- Open the cover on the LFU ’s connection box.
- Disconnect the heating element cables in the connection box according to the table.
| | Side | Cables 85 Ohm | Watt |
| Heating Element (1) | 1 | A30W1253 | 1050 |
| 2 | A30W2253 | 1050 |
| Heating Element (2) | 1 | A30W1242 | 1050 |
| 2 | A30W2242 | 1050 |
| Heating Element (3) | 1 | A30W1252 | 1050 |
| 2 | A30W2252 | 1050 |
| Heating Element (4) | 1 | A30W1242 | 1050 |
| 2 | A30W2242 | 1050 |
| Heating Element (5) | 1 | A30W1251 | 1050 |
| 2 | A30W2251 | 1050 |
| Heating Element (6) | 1 | A30W1241 | 1050 |
| 2 | A30W2241 | 1050 |
| | Side | Cables 95 Ohm | Watt |
| Heating Element (7) | 1 | A30W1244 | 600 |
| 2 | A30W2244 | 600 |
| Heating Element (8) | 1 | A30W1254 | 600 |
| 2 | A30W2254 | 600 |
- Measure the resistance of the heating elements from the connection box. The resistance must be in the range according to the table. If the resistance is out of range, change the heating element. See Transfer Unit - Change Heating Element.Note: Measure the resistance values when the unit is cold.
- Reassemble the cover on the LFU connection box.
Burn hazard.Allow the transfer unit to cool down before starting any work on it.The transfer unit and its connections can be hot.
Switch the MAIN POWER to ON and step up the machine to heating.- When the working temperature is reached, check all connections for leakages.
- Check the Heated Plastic Hose for leakages.
- Check the Water Connection for leakages.
- Check for Check for Oil Leakage on the Gear box. For more information, see Procedure 3.2-10 LFU - Gearbox Oil Table.

- Gear box
- Check for Oil Leakage
- Water Connection
- Heated Plastic Hose
Transfer Unit - Set Frequency
| Equipment Status | Program Step Production |
Check
Set low speed
Fine adjustments must be performed for every individual unit. See section Settings on page Settings for basic setting values.When the frequency for low speed is set correctly, the extruder motor works mainly in low speed mode and occasionally change to high speed mode (not to stop). The ideal setting is if the motor works continuously at low speed without interruptions.- Step the machine up to production.
- Make sure that the two sensors are not activated. If they are, the extruder works with an over capacity and regulates between low speed and stop, which causes unnecessary high stress on the motor and gearbox.
- If necessary, decrease the frequency for low speed.
Set high speed
The frequency for high speed mode must be approximately 20% higher than the low speed frequency. The setting of the high speed is most critical the first time, after the machine has been stepped down to out of heating.- Step the machine up to production.
- Observe the accumulator and the sensors during the first ten LFU cycles. If the accumulator at any time reaches the upper mechanical stop (the plastic accumulator is empty), the frequency for high speed must be increased.
- If necessary, increase the frequency for high speed.
Transfer Unit - Set Inductive Sensors
| Equipment Status | Program Step |
Setting the Inductive sensor.There are two different sensor types:- Machines with T-order numbers up to 63202/20066 have Omron EZA-type sensors with total sensor length = 43 mm.Set the distance between the Inductive sensor and the Sheet to A = 1.8 ± 0.2mm.
- Machines with T-order numbers from 63202/20066 have IFM 5379-type sensors with total sensor length = 50 mm.Set the distance between the Inductive sensor and the Sheet to A = 1.0 ± 0.2mm.

- Inductive sensor
- Sheet
Transfer Unit - Clean
| Equipment Status | Power must be turn OFF.
|
| Special Equipment | Vice with soft jaws Hydraulic service hoses: TP No. 1116468 Cleaning wire brush: TP No. 1309620 Drive mandrel: TP No. 2888711 |
| Consumables | Seal: TP No. 1573956 Anti-seize lubricant: TP No. 344443-0000 Assembly paste: TP No. 344418-0000 Thread sealant: TP No. 344447-0000 |
Burn hazard.Allow the transfer unit to cool down before starting any work on it.The transfer unit and its connections can be hot.
- Clean the transfer unit because:
- Filthy objects may have come into the transfer unit.
- Dirt from the granulate may have accumulated.
- Step the machine down to step zero.
- Remove the LFU from the machine. See LFU - Move to Service Position.
- Remove the transfer unit. See Transfer Unit - Remove.
- Remove the Screw. Clean the Lid.

- Screw
- Lid
- Connect an electrical cable to the four heating elements in the front.Note: To dismantle and clean the transfer unit barrel, the connection, the screw, and the temperature of the transfer unit must be hot. Use brass or aluminium tools and a cleaning wire brush when cleaning.
- Remove the lid from the back of the gearbox.
- Apply assembly paste to the Drive mandrel screw.
- Attach the Drive mandrel to the gearbox and centre it against the hole axle.
- Push the Transfer unit screw from the rear with the Drive mandrel until it can be reached with a pair of pliers.
- Pull out the Transfer unit screw with a pair of pliers.
- Put the Transfer unit screw in a vice with soft jaws.
- Clean the Transfer unit screw and all dismantled parts with a scraper and a wire brush to remove the plastic while it is still hot.
- Clean the barrel of the transfer unit and the granulate inlet with the Cleaning wire brush to remove all plastic. Remove the electrical cable to the heating elements.
- Apply anti-seize lubricant to the top of the threads in the Transfer unit screw. Do not use any other oil or grease on the Transfer unit screw.
- Apply assembly paste to the shaft end and the key slot of the Transfer unit screw.
- Put the Transfer unit screw back into the barrel. Fit the key inside the barrel.

- Drive mandrel
- Transfer unit screw
- Cleaning wire brush
- Apply thread sealant on the Blind plug and assemble.
- Assemble the Seal on the Lid.
- Apply assembly paste on the Screw.

- Screw
- Lid
- Transfer unit screw
- Blind plug
- Seal
- Tube
The gap A around the Lid must be even for an even compression of the seal.- Tighten the Screw in sequence from C1 to C6. For the first lap, tighten each screw by hand. For the second lap, tighten each screw to a torque of 30 Nm. For the third lap, increase the torque to 60 Nm, and so on for the values listed until reaching a final torque of 136 Nm on each screw.
| Lap | Torque |
| 1 Hand tighten | |
| 2 | 30 Nm |
| 3 | 60 Nm |
| 4 | 90 Nm |
| 5 | 136 Nm |
Note: Check the gap A between the Tube and the Lid with a feeler gauge during the tightening so it does not become uneven.Note: The screws must not be loosened after tightening because the seal has been plastically deformed. If the screws are loosened, the seal must be replaced. 

Pattern for tightening the screws
A = A
- Lid
- Tube
- Fit the transfer unit, see Procedure Transfer Unit - Remove, and perform the procedure in reverse order.
- Install the LFU. See Procedure LFU - Install from Service Position.

- Screw
- Lid
- Seal
Transfer Unit - Remove
| Equipment Status | Power must be turn OFF. Program Step |
| Special Equipment | Hydraulic service hoses, TP No. 1116468 Assembly tool, TP No. 1551475-0101 |
- Remove the LFU from the machine, see LFU - Move to Service Position on page LFU - Move to Service Position.
Burn hazard.Allow the transfer unit to cool down before starting any work on it.The transfer unit and its connections can be hot.
Hazardous voltage.The main power supply disconnector must be switched off and secured with a lock before starting any work on the electrical equipment. Will shock, burn or cause death.
- Disconnect the Heated hose from the accumulator.
- Loosen the Bracket with sensors.
- Remove the Dosing unit and plug the holes.
- Disconnect the Cable Connection from the heating elements and the sensors.Note: Label all cables before disconnecting them.
- Disconnect the fuse from the Motor according to EM.
- Disconnect the motor cable from the Motor.
- Disconnect the two Water hose and the Air hose.

- Heated hose
- Bracket with sensors
- Dosing unit
- Cable Connection
- Motor
- Water hose
- Air hose
- Fit the Assembly tool to the frame.
- Remove the four Screw and roll out the transfer unit.Note: Be careful with the thermocouples when rolling out the transfer unit.

- Assembly tool
- Screw
Transfer Unit - Change Bearing Unit, Drive Unit, Geared Motor
| Equipment Status | Power must be turn OFF.
|
| Special Equipment | Mounting tool: TP No. 1551475-0100 Drive mandrel: TP No. 2888711 Drive mandrel: TP No. 2864304 |
| Consumables | Anti-seize: TP No. 344418-0000 |
- Roll out the LFU. See Procedure LFU - Move to Service Position on page LFU - Move to Service Position.
Hazardous voltage.The main power supply disconnector must be switched off and secured with a lock before starting any work on the electrical equipment.Will shock, burn or cause death.
Burn hazard.Allow the transfer unit to cool down before starting any work on it.The transfer unit and its connections can be hot.
Disconnect the fuse from the Motor according to the EM.- Disconnect the motor cable from the Motor.

- Motor
- Remove the Connection box.
- Remove the flow meter unit fastening screws and the Flow meter unit.
- Remove the four transfer unit connection box fastening Screw.
- Remove the Dosing unit and plug the hole.

Right: View from bottom
- Connection box
- Flow meter unit
- Screw
- Dosing unit
Prevent the transfer unit screw from falling down.
- Put a wooden Plank/beam or similar on the frame and fasten the strap around the Bearing unit and the plank/beam.
- Fasten a strap around the Beam and the transfer unit.

- Plank/beam
- Bearing unit
- Beam
Fit the assembly tool
- Fit the Assembly tool to the frame.

- Assembly tool
Loosen the transfer unit
- Remove the four transfer unit fastening Screw.
- Remove the two transfer unit fastening Screw.
- Remove the two transfer unit fastening Screw.

- Screw
- Screw
- Screw
Split the transfer unit screw from the bearing unit (only for bearing unit or drive unit)
- Remove the six transfer unit fastening Screw.
- Remove the cover and fit the Drive mandrel TP No. 2888711.
- Apply anti-seize on the threads of the Drive mandrel TP No. 2888711.
- Turn the Drive mandrel TP No. 2888711 while removing the Transfer unit screw from the bearing unit.
- Roll out the transfer unit.Note: Be careful with the thermocouples when rolling out the transfer unit.
- Remove the Drive mandrel TP No. 2888711.

- Screw
- Drive mandrel TP No. 2888711
- Transfer unit screw
Remove the bearing unit (only for bearing unit or geared motor)
- Remove the eight bearing unit fastening Screw.
- Fit the Drive mandrel TP No. 2864304.
- Apply anti-seize on the threads of the Drive mandrel TP No. 2864304.
- Turn the Drive mandrel TP No. 2864304 and remove the Bearing unit.

- Screw
- Drive mandrel TP No. 2864304
- Bearing unit
Install (bearing unit)
- Apply anti-seize on the new Bearing unit shaft.
- Assemble the new bearing unit.
- Apply anti-seize on the Transfer unit screw shaft.Note: Check that the wedges in the new bearing unit and the Transfer unit screw shaft are aligned. If not, remove the Fan cover on the transfer unit and turn the fan until the wedges are aligned.
- Assemble in the reverse order.

- Bearing unit shaft
- Transfer unit screw shaft
- Fan cover
Install (drive unit)
- Apply anti-seize on the transfer unit screw shaft.Note: Check that the wedges in the new bearing unit and the transfer unit screw shaft are aligned. If not, remove the Fan cover on the transfer unit and turn the fan until the wedges are aligned.
- Assemble in the reverse order.

- Fan cover
Install (geared motor)
- Apply anti-seize on the bearing unit shaft.Note: Check that the wedges in the bearing unit and the geared motor are aligned. If not, remove the Fan cover on the transfer unit and turn the fan until the wedges are aligned.
- Assemble in the reverse order.

- Fan cover
- Enable the breathing function for the Gear Box by removing the Transportation lock on the Valve before the motor is started.

- Valve
- Transportation lock
Transfer Unit - Change Heating Element
| Equipment Status | Power must be turn OFF.
|
- Remove the Screw.
- Remove the Heating element.
- Install a new Heating element.
- Install the Screw.

- Screw
- Heating element
- Make sure that the distance between the two heating elements is about 35mm in every zone and that the heating elements are centred around the Sensor.

A ≈ 35 mm
- Heating element
- Sensor
Accumulator - Change Heating Hose
| Equipment Status | Program Step step ZERO |
| Consumables | Anti-seize TPNo.344418-0000 |
If the Heating hose has poor durability and is leaking, see Alarm 110303481/110303491/110303482/110303492 "Injection Cylinder Not Filled".- Disconnect the Cable from the Connection box.
- Loosen the Nut and disconnect the Heating hose from the Accumulation unit.

- Heating hose
- Cable
- Connection box
- Nut
- Accumulation unit
- Loosen the Nut and disconnect the Heating hose from the Hot channel.

- Heating hose
- Nut
- Hot channel
Risk of damage to the equipment.Make sure that the
Heating hose is installed correctly.The
Heating hose must be installed without being twisted, otherwise it can break.
- Check the Connection for damage and wear. If necessary, replace the connections and the Seal.Note: It is important that the seals are also replaced.Note: If the nuts on the current Heating hose have been overtightened, it can have caused worn or damaged threads and conical surfaces of the Connection. Damaged threads and surfaces require a higher torque than recommended (45Nm). A higher torque than recommended can result in a twisted heating hose and reduce the lifetime of the heating hose.
- Fit the Connection to the accumulation unit and the hot channel. Tightening torque 80Nm.
- Change the Heating hose.
- Apply anti-seize on the marked areas in the illustration below.Note: Make sure that there is no anti-seize on the conical surfaces of the heating hose nipples or the conical surfaces inside the Connection.Note: Anti-seize on the conical surfaces can result in twisting the heating hose during tightening, and reduce its lifetime.
- Assemble the Heating hose. Tightening torque 45Nm.Note: Close the outer tools before assembling the Heating hose.
- Assemble in the reversed order.

- Heating hose
- Connection
- Seal
Accumulator - Overhaul
| Equipment Status | Program Step STEP ZERO |
| Consumables | Grease: TP No. 344469-7277 |
- Disconnect the Air hose and the Water hose.
- Remove the Screw and the Holder.
- Remove the Screw and the two Bracket.
- Remove the Cylinder.Note: The Cylinder can be firmly attached due to hardened plastic.
- Turn the Cylinder upside down and remove the Piston.
- Remove the Seal.Note: Note the direction of the Seal.
- Lubricate the new seal ring with grease.
- Assemble in the reverse order.

- Air hose
- Water hose
- Screw
- Holder
- Screw
- Bracket
- Cylinder
- Piston
- Seal
Metering Device - Set
| Equipment Status | Program Step |
Capacity Sensor - Set Valid For 90458-1840
- Remove the Connection, loosen the Counter Nut.
- Adjust the Capacity Sensor to distance A.
- Tighten the Counter Nut, assemble the Connection.Note: Align the Capacity Sensor with the Potentiometer upwards!
- Make sure that there is no granulate in front of the Capacity Sensor.This due to the coming sensitivity setting. The sensor must have a granulate free area to the next side of the tube.
- Set the sensitivity with the Potentiometer:

A (mm) = 48 ± 2
- Connection
- Capacity Sensor
- Counter Nut
- Indicator
- Potentiometer
Capacity Sensor - Set Valid For 90608-5054
- Remove the Connection, loosen the Counter nut.
- Adjust the Capacity sensor to distance A.
- Tighten the Counter nut, assemble the Connection.
- Make sure that there is no granulate in the front of the Capacity sensor.This due to the coming sensitivity setting. The sensor must have a granulate free area to the next side of the tube.
- Set the sensitivity with the Potentiometer:

A (mm) = 41 ± 2
- Connection
- Capacity sensor
- Counter nut
- Potentiometer
- Green LED
- Yellow LED
Cylinder Set
- Adjust the Cylinder to distance B.
- Align the Air Connections, as seen on the illustration.

B (mm) = 14 ± 0.7
- Cylinder
- Air Connections
Metering Device - Change Pneumatic Cylinder
| Equipment Status | Program Step |
Change
- Note the numbers on the air hoses, also note to which of the Connections it is connected to.
- Remove the air hoses.
- Loosen the Counter nut, and remove the double acting Cylinder.
- Assemble in the reverse order.
Set
- Set the cylinder, see Procedure Metering Device - Set.
- Tighten the Counter nut.
- Put the air hoses back on the Connections.Note: Make sure that the air hoses are refitted on the same Connections, as they used to be in. Otherwise will the function of the double acting cylinder be faulty, with a wrong dosing as a result.

- Cylinder
- Counter nut
- Connections
Metering Device - Install
| Equipment Status | Power must be turn OFF. Program Step |
Note: Assemble the seal according to the illustration.- Assemble the Seal and the inner of the Screw on the Transfer unit.
- Assemble the Container on the Transfer unit and tighten the Screw.
- Assemble the Capacitive sensor, with the cable pointing downwards.Note: The end of the Capacitive sensor must be aligned with the inner diameter on pipe at Container.
- Assemble the granulate Hose, sealing and Clamp.Note: It is important that distance A (between the pipes) is maximum 100 mm, otherwise there is a risk for granulate stagnation, see .

- Capacitive sensor
- Container
- Clamp
- Screw
- Seal
- Transfer unit
- Hose
- Round hole
Note: Assemble the Hose according to the notations, made earlier.- Assemble the air Hose in the Pipe coupling on the Cylinder.
- Assemble the Lid and the Spring on the Container.
- Open the granulate valves.

- Container
- Cylinder
- Hose
- Lid
- Spring
- Pipe coupling
Description
The Servo motor handles the opening and closing of the external tools together with the vertical force cylinder.The Servo motor drives a Belt that is connected to a Shaft. The Shaft has Toothed pulley where the Timing belt are attached.The pivot point of the Link arm creates the movement pattern of the external tools.
- Servo motor
- Belt
- Shaft
- Toothed pulley
- Timing belt
- Link arm
Drive Tool - Set Belt Tension
| Equipment Status | Program Step |
| Special Equipment | Dynamometer, TP No. 74767 or alternatively a Belt Tension Meter, TP No. 90459-2181 |
Check belt tension
- Remove the Screw, the Screw, and the two belt Holder.

- Screw
- Holder
- Screw
- Check the belt tension:
- With a Dynamometer: Press at the centre of the belt with a force of 50 N. The distance between the belt surfaces should be according to distance A.
- With a Belt tension meter: a frequency of 60 ±2 Hz.

A (mm) = 55 ±1
- Dynamometer
- Belt tension meter
Set belt tension
- Remove the Screw.
- Set the belt tension by tightening the Screw.
- Check the belt tension during the setting. See Procedure Check belt tension
- Fit and tighten Screw with a torque of 22 ±2 Nm.

A (mm) = 55 ±1
- Screw
- Screw
- Assemble the Holder and tighten the Screw and the Screw gently. Make sure that the Mounting lug is aligned with the Frame piece.Note: If the Mounting lug and the Frame piece are not aligned, the belt tension will differ between the outside and the inside of the belt.
- Install the belt cover.
- Step the machine up to program step heating.
- Use the remote control, see ProcedureLFU Remote Control - Handle and activate:
- To centre the tool beams, loosen the Screw and the Screw, then tighten them right back.
- Tighten the Screw and the Screw to 22 Nm.

- Screw
- Holder
- Screw
- Mounting lug
- Frame piece
Drive Tool - Change Belts
| Equipment Status | Program Step |
This procedure must be performed on both sides of the drive tool.- Remove the Screw.
- Release the belt tension by loosening the Screw.
- Remove the Screw, the Clamp, and the Mounting lug.
- Change the timing belts.Note: Make sure that the Slot on the Toothed Pulleys are upwards. Also note the positions of the Screw. They must be moving between the belts inner side according to the illustration.
- Set the tension of the timing belts, see sub procedure Drive Tool - Set Belt Tension on page Drive Tool - Set Belt Tension.

- Screw
- Screw
- Screw
- Clamp
- Mounting lug
- Slot
- Toothed Pulleys
- Screw
Drive Tool - Assemble
| Equipment Status | Program Step |
| Special Equipment | Puller TP No. 1573950 0.5 mm feeler gauge |
- Assemble the holder and connect it to the hot channel, see Procedure Guide Hot Channel - Overhaul.
- Fit the bars (see arrows) and set according to the instruction LFU - Basic Set in Procedure LFU - Basic Set.
- Fit the Ball bearing on to the Shaft.
- Fit the Shaft through the Bearing house.
- Fit the Toothed pulley and the Motor belt.
- Fit the Retaining ring, Ball bearing, Ring, and Bearing into the Bearing house. If needed, warm up the bearing house by a hot air-gun.
- Warm up the Bearing house with a hot-air gun. Use the Puller TP No. 1573950 and press the Shaft through the Bearing, Ball bearing and the Bearing house. The Ring must be lifted up.
- Fit the Retaining ring.
- Fit the Toothed Pulley and align according to illustration below, tighten with 22 Nm.Note: It is important that the screw and the slots in the Toothed pulley and Toothed Pulley are aligned as illustration shows, otherwise there will be a rapid wear in the belts!
- Fit a 0.5 mm feeler gauge between the Toothed pulley and the Bearing house. Tighten the screws to the Toothed pulley to a torque of 9.3 Nm.

- Ball bearing
- Shaft
- Bearing house
- Toothed pulley
- Motor belt
- Retaining ring
- Ball bearing
- Ring
- Bearing
- Bearing house
- Puller TP No. 1573950
- Retaining ring
- Toothed Pulley
- Assemble the servomotor, see Procedure Motor Unit - Change.
- Fit the Ball bearing and the Retaining ring into the Toothed pulley.
- Press one of the Toothed pulley on to the Shaft and fit the Sleeve onto the shaft.
- Fit the shaft in to the Bearing house and Bearing house.
- Fit the Sleeve.
- Fit the Puller TP No. 1573950 and press the other of the Toothed pulley on to the shaft.
- Fit the Retaining ring.
- Assemble the timing belts, see Procedure Drive Tool - Change Belts.

- Puller TP No. 1573950
- Ball bearing
- Retaining ring
- Toothed pulley
- Shaft
- Sleeve
- Bearing house
- Bearing house
- Sleeve
- Retaining ring
Motor Unit - Remove Cover
| Equipment Status | Program Step |
- Loosen the Screw.
- Remove the Belt cover.

- Screw
- Belt cover
Motor Unit - Set Belt Tension
| Equipment Status | Program Step |
| Special Equipment | Dynamometer, TP No. 74767 alternative Belt Tension Meter, TP No. 90459-2181 |
Burn hazard.Allow the LFU to cool down before starting any work on it.The area around the servomotor can be hot.
Check belt tension
Check the belt tension:- With a Dynamometer, press at the centre of the belt with a force of 50 N. The distance between the belt surfaces should be according to distance A.
- With a Belt tension meter: a frequency of 136 ±2 Hz.

A = 63 ±1 mm
- Dynamometer
- Belt tension meter
Set belt tension
- Loosen the Screw and counter nuts on the Screw.
- Adjust on the Screw and check the belt tension during the setting.
- Tighten the counter nuts for the Screw and fit the belt protection cover.
- Tighten the Screw on the servomotor.

- Screw
- Screw
Motor Unit - Change Belt Contact Surface
| Equipment Status | Program Step |
- Make a mark with a pen according to the arrow in the illustration below.
- Disconnect the motor cable.
- Remove the Screw and nut.
- Remove the Screw, Screw, and Bracket.
- Remove the four Screw and remove the Servomotor.
- Move the mark on the Belt 100 mm upwards.
- Assemble in the reverse order.Note: Make sure that the mark is 100 mm upwards from its original position.

A (mm) = 100
- Screw and nut
- Screw
- Bracket
- Screw
- Servomotor
- Screw
- Belt
Guide Stripper - Set
| Equipment Status | Program Step HEATING |
| Special Equipment | 2.0 mm and 2.5 mm feeler gauges |
- Remove the Screw from the Bracket and disconnect the cam wheel connection.
- Slide the Guide forward and backward by pushing and pulling the Bracket. Check that the Guide moves easily on the Rod.Note: It is important to push and pull the Bracket to imitate the machine movements.

- Screw
- Bracket
- Guide
- Rod
- Place sleeves on a pair of Mandrel and turn them downwards.
- Use the remote control, see Procedure LFU Remote Control - Handleand activate:
- Step 1 High Pressure
- Step 2 Locking Scissors
- Close Tools Manually
- Step 3 Horizontal Force
- Check distances A, B, C, and D. The difference between them must not exceed 0.5 mm, this is to avoid unnecessary wear on the Mandrel.

- Mandrel
Note: Do not loosen the Screw, Screw, or Screw. If this is done, the LFU settings will be altered.- If necessary, loosen the Screw to adjust the Guide and then repeat item Reference above.

- Guide
- Screw
- Screw
- Screw
- Screw
- Try to press in a 2 mm feeler gauge between the Stripper and the Mandrel. See arrows in the illustration.
- If the 2 mm feeler gauge fits, repeat item Referencewith a 2.5 mm feeler gauge. If the 2.5 mm feeler gauge does not fit, the distance E is correct.
- If the 2 mm feeler gauge does not fit, the height must be adjusted by adding Shim between the Beam and the Beam and the Guide.
- Repeat item Reference until the distance E is correct.
- Use the Screw to attach the Bracket to the cam wheel connection.

E (mm) = 2.0 +0.5/-0
- Screw
- Bracket
- Guide
- Mandrel
- Shim
- Beam
- Beam
Guide Stripper - Lubricate
| Equipment Status | Program Step step Zero |
| Special Equipment | Grease gun: TP No. 3366407-0000 |
| Consumables | Grease: TP No. 344407-0000 |
Use one stroke from a Grease gun to lubricate the Guide through the Grease nipple.Note: Do not over lubricate the guide. Remove surplus lubrication.
- Grease gun
- Guide
- Grease nipple
Guide Stripper- Overhaul
| Equipment Status | Program Step |
| Special Equipment | Drive mandrel TP No. 2811656 |
- Remove the four Ball bushing by using the Drive mandrel TP No. 2811656.
- Change the four Ball bushing.
- Check the Spring for wear or damage. Change if necessary.Note: Before fitting, remove the Sealing pointing inwards, this to make it able for the grease to lubricate the rods.

- Ball bushing
- Drive mandrel TP No. 2811656
- Spring
- Sealing
Stripper - Check
| Equipment Status | Program Step |
- Check that the forward edges of the Plastic stripper are sharp and undamaged.
- Check the springs function by pressing the strippers.

- Plastic stripper
Stripper - Change
| Equipment Status | Program Step |
- Remove the four Screw and remove the stripper from the LFU.
- Remove the Screw.
- Remove the Cover, the Plastic stripper, and the Spring.
- Change the Plastic stripper and the Spring, and press them into position.
- Assemble the stripper in the reverse order.
- Check that all of the Plastic stripper moves freely.

- Screw
- Screw
- Cover
- Plastic stripper
- Spring
Tools - Check Lid
Topic included in MM and UP for Conv. Kit Openings | Equipment Status | Program Step step zero |
| Special Equipment | Calibrated micrometre 0 mm to 1.00 mm Opening force tester, TP No. 2768297-0100 |
Checking the lid thickness and opening force gives a good indication of the condition of the lid forming unit (LFU).If the opening values are within limits according to specified values in the OM-PC, no further setting is necessary.The lid thickness gives a good picture of the condition of the tools knife edge. - Thick, tight lids with a low opening force indicate good condition.
- Thin lids with a high opening force indicate bad condition or settings. See LFU - Troubleshooting.
Opening Force
- Pick eight consecutive packages from each side.
- Perform an opening test with the opening tester. Follow the instructions in the OM-PC.To identify from which mandrel/tool the lids come from, look for the mark inside the lids. For more information about tool identification, see the OM-PC.
- Note the tool number on the lid.
Lid Thickness
- Use the same packages used for the opening force test.
- Measure the lid thickness according to instructions in the OM-PC.
- If problems occur, check the lid thickness on the membrane and on the top, as near the top sleeve overlap as possible. Check on the LS side and on the opposite side.
Check Neck Thickness
Valid for: A38 Cap- To be able to perform a neck thickness test, the following equipment is needed:
- Copy the test form Test Form for Neck Thickness.
- Fill in the general information.
- Collect packages after the packaging machine or after the Capper 60 (remove the cap from the package).
- Remove the membrane. Use a knife to pierce at the recess. Carefully tear off the membrane.
- Write down the inner tool number. For more information, see the OM-PC.
- Mark the measuring positions according to the illustration.

LS side

Front side
- Cut the top in half, along the line between the front tool and the rear tool.
- Cut off the dome (see the following illustration).
- Measure the thickness of the neck at the six marked positions, in the shaded area.
| Opening | Minimum Thickness (mm) | Maximum Thickness (mm) |
| MiniV Nallo A38 | 0.65 | 0.8 |
| Mini Taishan A38 | 0.65 | 0.8 |
| Midi Idum A38 | 0.65 | 0.8 |
- If any of the measured values are out of range, set the centre of the external tools and measure the thickness again. See Procedure External Tools - Set Centre of Tools.
External Tools - Check
Topic included in MM and UP for Conv. Kit Openings | Equipment Status | Program Step step zero |
Burn hazard.Allow the LFU to cool down before beginning any work on it.The external tools can be hot.
Risk of damage to the equipment.Handle the tools with care.The tools are manufactured with high precision and can easily be damaged.
Check
- Produce package samples before capping. Check the packages according to Chapter 4 Destructive Checks in OM - Package Checks.
- Remove the external tools. See Procedure External Tools - Remove.
- Check all the surfaces around the External tool front and the External tool rear parts of the tools for wear and damage. Make sure that the surface treatment on the underside of the tools is not damaged.Note: If the wear is severe, perform a basic setting. See Procedure .
- Check the Surface between the tool halves and the inside of the tools, particularly to make sure that the Knife edge is intact.
- If there is water leakage, remove the Tool holder and change the O-ring.
- Fit the tools. See Procedure External Tools - Install.

- External tool front
- External tool rear
- Surface
- Knife edge
- Tool holder
- O-ring
External Tools - Check Distance
Topic included in MM and UP for Conv. Kit Openings | Equipment Status | Program Step heating |
| Special Equipment | Feeler gauge |
| Checked Item | Pass Criteria |
| Distance A | A ≥ 2.5 mm |
- Use the remote control to perform the following steps. See Procedure LFU Remote Control - Handle.
- When the LFU is up in working temperature, start:
- Step 1 High Pressure
- Step 2 Locking Scissors
Risk of crushing.Make sure that the
Scissor is properly locked.There are moving parts in the machine.
To lock the Scissor, fit a screw trough the Pin in the Scissor and tighten with a nut.
- Scissor
- Hole
- With the LFU Remote Control, step down to Step 1 High Pressure.
Risk of damage to the equipment.Handle the tools with care.The tools are manufactured with high precision and can easily be damaged.
Burn hazard.Allow the LFU to cool down before beginning any work on it.The external tools can be hot.
- Measure the distance A between the front and rear External tools with a feeler gauge.
- If the distance A < 2.5 mm, contact TetraPak Technical Liaison.

A ≥ 2.5 mm
- External tools
External Tools - Set Centre of Tools
Topic included in MM, UP for Conv. Kit Openings and UP for OK Nallo. | Equipment Status | Program Step HEATING |
Burn hazard.Allow the external tools to cool down before beginning any work on them.The external tools can be hot.
Risk of damage to the equipment.Handle the tools with care.The tools are manufactured with high precision and can easily be damaged.
Note: The external tools can be set with the LFU in the machine.- For tools with FIXED bushing, go to item Reference.
- For all other tools:
- Run at least two sleeves.
- Put the sleeves on a pair of mandrels.
- Loosen the Screw and the Screw. Make sure that the Plate and the External tool are loose.
- Make sure that the pair of mandrels is positioned into the external tools.

- Screw
- Screw
- Plate
- External tool
For instructions regarding handling of the remote control and recharging the accumulator. See Procedure LFU Remote Control - Handle.- Insert and turn on the service key.
- Choose
LFU Service S1 or LFU Service S2. - Start step 1 (Hydraulic high Pressure).
- Start step 2 (Lock). Close the tools with the recharging accumulator.
Risk of crushing and cutting.Enclose the area around the LFU. Make sure that no unauthorised personnel can come in contact with the LFU.The movement in the LFU can cause injuries.
Start step 3 (Horizontal Force).
- Check that the sleeves are not pinched between the tool halves.
- Tighten the Screw to 10 Nm.
- Tighten the Screw to 10 Nm.
- Step the machine down in the reverse order.
- Check the sleeve for pinch marks.
- For Taishan A38 and Idum A38, check the neck thickness. See Procedure Section Tools - Check Lid in Procedure Tools - Check Lid.

- Screw
- Screw
External Tools - Clean
Topic included in MM and UP for Conv. Kit Openings | Equipment Status | Program Step step zero |
| Consumables | Alcoholic solution (Isopropanol 70%) |
Burn hazard.Allow the LFU to cool down before beginning any work on it.The external tools can be hot.
Risk of damage to the equipment.Handle the tools with care.The tools are manufactured with high precision and can easily be damaged.
Note: The external tools can be cleaned with the LFU in the machine.- Clean the External tool with 70% isopropanol. See Section Chemicals for Cleaning and Disinfection.
- Dry the External tool with a clean cloth.Note: The tools must be free from grease, dust, and moisture.

- External tool
External Tools - Remove
| Equipment Status | Program Step step zero |
| Special Equipment | Hex key Soft hammer |
Hot Surface.Allow the LFU to cool down before beginning any work on it.The external tools can be hot and cause burns.
Risk of damage to the equipment.Handle the tools with care.The tools are manufactured with high precision and can easily be damaged.
Note: The external tools can be removed with the LFU inside the machine.- Disconnect the Quick connection for cooling water from the LFU.Note: Avoid getting cooling water on the hot channel. Water on the hot channel and its connections can cause an earth fault and lead to prolonged production disturbances.
- Drain the remaining water out from the LFU by pressing the nonreturn valve Quick connection.

- Quick connection
- Remove the four Screw.Note: Before removing, mark the tools, “1:1” and “1:2”.
- Remove External tool.

- Screw
- External tool
- Save the Water connection tube for later installation of the external tools.

- Water connection tube
External Tools - Install
| Equipment Status | Program Step step zero |
| Consumables | Silicone grease, TP No. 344477-0000 |
Risk of damage to the equipment.Handle the tools with care.The tools are manufactured with high precision and can easily be damaged.
Note: The external tools can be installed with the LFU inside the machine.- Apply silicone grease on the O-ring.
- Assemble the Water connection tube in the External tool before fitting the tool on the Tool holder.
- If the fitted tools are new, align the tools. See Procedure External Tools - Set Centre of Tools.

- O-ring
- Water connection tube
- External tool
- Tool holder
- Fit the External tool according to the marking (rear and front).
- Fit and tighten the Screw to a torque of 10Nm.

- External tool
- Screw
- Connect the Quick connection for the cooling water to the LFU.

- Quick connection
Valid for: Mini Taishan A38Identification of moulding station on the package (introduced as standard from machine number 63202/20208)With the tools mounted in the machine, it is possible to identify the side (S1:1, S1:2 or S2:1, S2:2) where the package was produced. The side is identified with visual inspection of the package directly after the machine.- To enable this feature, change the Tool Front Mini 3634697-1 to the Tool Front Mini 3634697-2.Note: It is suggested to change the tools on station S1:1 and S2:2.

- Tool Front Mini 3634697-1
- Tool Front Mini 3634697-2
- A small Mark is added on the plastic top for identifying the package without opening it. The Mark is put on the small horizontal surface below the threads. It is put on the same side as the longitudinal seal on the package.

- Mark
External Tools - Check Distance
| Equipment Status | Program Step heating |
| Special Equipment | Feeler gauge Locking Loop, TP No. 3674453-0000 |
- Use the remote control to perform the following steps. See Procedure LFU Remote Control - Handle.
- When the LFU is up in working temperature, start:
- Step 1 High Pressure
- Step 2 Locking Scissors
Risk of crushing and cutting.Enclose the area around the LFU and make sure that no unauthorised personnel can come in contact with the LFU.The movement in the LFU can cause injuries.
Install the Locking Loop in the Hole in the Scissor and lock it with the Pin.
- Locking Loop
- Hole
- Scissor
- Pin
- With the LFU Remote Control, step down to Step 1 High Pressure.
Risk of damage to the equipment.Handle the tools with care.The tools are manufactured with high precision and can easily be damaged.
Burn hazard.Allow the LFU to cool down before beginning any work on it.The external tools can be hot.
- Measure the distance A between the front and rear External tools with a feeler gauge.The distance A must be at least 2.5mm.
- If the distance A is less than 2.5mm, contact TetraPak Technical Liaison.

A > 2.5 mm
- External tools
Internal Tools - Check
Topic included in MM and UP for Conv. Kit Openings | Equipment Status | Program Step step zero |
Risk of damage to the equipment.Handle the tools with care.The tools are manufactured with high precision and can easily be damaged.
Note: The internal tools can be checked with the LFU in the machine with the tools remaining on the mandrels.- Valid for: PullBridge
- Check that the entire tool is intact and that the coating is not missing.
- Check that the Knob is not worn down or completely missing.
- Check that the Knife is intact.
- Valid for: Spiral
- Check that the entire tool is intact and that the coating is not missing.
- Check that the Knife is intact.
- Valid for: BridgeTwist
- Check that the entire tool is intact and that the coating is not missing.
- Check that the Knife is intact.
- If necessary, change the internal tools.See procedure Internal Tools - Remove and Internal Tools - Install.

PullBridge

Spiral

BridgeTwist
- Knob
- Knife
- Valid for: Huron
- Check that the entire tool is intact and that the coating is not missing.
- Check that the Knife is intact.
- Valid for: Saroma
- Check that the entire tool is intact and that the coating is not missing.
- Check that the Knife and the Tip is intact.
- Valid for: Lokka
- Check that the entire tool is intact and that the coating is not missing.
- Check that the Knife is intact.
- If necessary, change the internal tools.See procedure Internal Tools - Remove and Internal Tools - Install.
- Valid for: Internal tool A38
- Check that the entire tool is intact and that the coating is not missing.
- Check the Surface and the Edge for dents and cracks.
- Valid for: Internal tool O38/C38 with FIXED bushing
- Valid for: Internal tool C38 with Spring-Loaded bushing
- Check the Surface for dents, cracks, and missing coating.
- Check that the Screw and the Cover is not missing.
- If necessary, change the internal tools.See procedure Internal Tools - Remove and Internal Tools - Install.

A38

O38/C38 with FIXED bushing

C38 with Spring-Loaded bushing
- Surface
- Edge
- Bushing
- Screw
- Screw
- Cover
Internal Tools - Remove
| Equipment Status | Program Step step zero |
| Special Equipment | Puller, TP No. 591976 (Base) Puller, TP No. 1298604 (Midi/Mini/Micro) Removal Tool, TP No. 1572245 Hex key Soft hammer |
Risk of damage to the equipment.Handle the tools with care.The tools are manufactured with high precision and can easily be damaged.
Note: The internal tools can be removed with the LFU inside the machine.- Disconnect the Quick connection for cooling water.
- Drain the remaining water from the LFU (press the nonreturn valve in Quick connection).
- Disconnect the hoses on the swivel.
- Drain the remaining water.

- Quick connection
- Crank the machine so that the internal tool is accessible to be removed.
- Use the Removal Tool (part 1) to remove the Plug.
- Remove the Screw with a hex key.
- Use the Removal Tool (part 2) to pull out the Sleeve.

- Removal Tool (part 1)
- Removal Tool (part 2)
- Plug
- Screw
- Sleeve
- Fit the Puller. Tap gently with a soft hammer underneath the Puller until the Internal Tool comes off the mandrel.

- Puller
- Internal Tool
Internal Tools - Install
| Equipment Status | Program Step step zero |
| Special Equipment | Plug Tool, TP No. 2742034-0000 Torque wrench, range 1 Nm to 5 Nm |
Risk of damage to the equipment.Handle the tools with care.The tools are manufactured with high precision and can easily be damaged.
See Section Identification of Tool/Mandrel/Lid.- Fit the O-ring, O-ring, and O-ring.Note: Always change to the new O-rings to prevent internal leakage.
- Align and fit the Internal tool so that it corresponds to the Locating Pin on the Mandrel.
- Press down the Internal tool by hand onto the mandrel, until there is no gap between the Internal tool and the Mandrel.
- Fasten the Internal tool with the Sleeve and the Screw. Tighten the Screw to 2.7 Nm.Note: Do not overtighten the screws.Note: Use new screws and sleeves if they are damaged or deformed. If using damaged or deformed sleeves, there is a risk that the inner tool can come loose.

- O-ring
- O-ring
- O-ring
- Locating Pin
- Internal tool
- Mandrel
- Sleeve
- Screw
- Plug
- Put the Plug into the Plug Tool.Note: Fit the Plug with a visible edge.
- Align the Plug Tool to the Plug Hole.
- Tap firmly on the end of the Plug Tool with a plastic hammer.
- Connect the quick connections for the cooling water to the LFU.

A > 0 mm
- Plug
- Plug Tool
- Plug Hole
Internal Tools - Change Bushing
Topic included in MM and UP for Conv. Kit Openings | Equipment Status | Program Step step zero |
| Consumables | Assembly paste, TP No. 6-4722950801 |
Risk of damage to the equipment.Handle the tools with care.The tools are manufactured with high precision and can easily be damaged.
- Remove the Screw and the Bushing.
- Apply paste on the new Screw.
- Assemble the new Bushing.
- Tighten the Screw to a torque of 5.5 Nm


Opening Eifel and Nallo
- Screw
- Bushing
Description
The internal cooling water system is only used for the LFU and cools the hot channels, the injection cylinders, and the transfer unit. The system uses city water together with propylene glycol.Cooling Water System LFU (Glycol Circuit)
Valid for Hot Channel Pistons Without Cooling
Valid for Hot Channel Pistons With CoolingCooling Water System - Check
| Equipment Status | Program Step step zero |
- Check for leakage and wear in the water installation (1).
- Check all the water connections (2):
- Leakage from the swivel. See arrow in the illustration.
- Pull the water hoses (3) outwards.Note: The water hoses must not come loose.If a water hose comes loose, cut off a little bit of the end, and put the hose back.
Risk of fire.Make sure that no packaging materials or hoses touch these hot surfaces.There are several hot surfaces on the LFU that can cause fires.
Check the hoses and make sure that they do not touch any of the hot surfaces. Make sure that all the hoses are installed and routed in a similar way to how they were when the LFU was delivered. Take the movement of the mechanism into consideration.- Remove any packaging material in and around the LFU.
- Check that the brackets and holders for the water installation are tightened, and not causing any unnecessary wear.

- Water Installation
- Water Connection
- Water Hose
Description
The lubrication system distributes lubricating oil to all machine parts lubricated by the central lubrication system of the machine.Lubricating System - Check
| Equipment Status | Program Step |
- Check that all Oil hose are filled with oil, and not are damaged.
- Check all hose connections.
- Check for oil leaks and excessive lubrication.
Risk of fire.Make sure that no packaging materials or hoses touch these hot surfaces. Take the movement of the mechanism into consideration.There are several hot surfaces on the LFU that can cause fires.
Check the hoses and make sure that they do not touch any of the hot surfaces. Make sure that all the hoses are installed and routed in a similar way to how they were when the LFU was delivered. Take the movement of the mechanism into consideration.- Remove any packaging material in and around the LFU.

- Oil hose
Description
Valve Ramp - Overview
- Valve, horizontal cylinder (S1/YA30K1229 S2/A30K2229)
- Valve, reference stop cylinder (S1/A30K1225, S2/A30K2225)
- Valve, injection cylinder (S1/A30K1227, S2/A30K2227)
- Valve, Distance cylinder (S1/A30K1228, S2/A30K2228)
- Valve, Tightness cylinder (S1/A30K1226, S2/A30K2226
- Valve, Recharging accumulator (S1/A30K1223, S2/A30K2223)
- Valve, Pressing cylinder (S1/A30K1222, S2/A30K2222)
- Valve, Logic element (S1/A30K1224, S2/A30K2224)
For more information about the sequence and functions of the hydraulic system, see Sequences for the LFU on page Sequences for the LFU.Pipe Work Hydraulic - Check
| Equipment Status | Program Step |
DescriptionThis check is made to prevent hydraulic oil leakage and risk for product contamination.CheckRisk of personal injuriesMake sure that the oil pressure is zero before checking the hoses for oil leakages.Pin hole leakages may penetrate your skin.
Keep the area clean from oil for easier detection of leakages.Leaking hoses shall be changed. Even a small leakage is enough for corrective action.- Check the Pipe for leakages.
- Check that the Bracket are firmly fastened.

- Pipe
- Bracket
- Check the Hydraulic hose for wear or other signs of fatigue.Note: Pay extra attention where the hoses may touch each other or other parts of the machine.Note: Pay extra attention to hoses with large movements.
Hot surfacesThe hot channel and the extruder can be hot.Risk of burns.
Risk of fire.Make sure that no packaging materials or hoses touch these hot surfaces.There are several hot surfaces on the LFU that can cause fires.
Make sure that all the hoses are installed and routed in a similar way to how they were when the LFU was delivered. Take the movement of the mechanism into consideration.Note: Pay extra attention to hoses with large movements.- Check the Hydraulic hose for pin-hole leakage by:
- checking the surroundings for oil residues.
- checking the Hydraulic hose close to the Clamp.
- checking all the hydraulic hoses close to the Crimp shell.
- checking all the hydraulic hoses where they change direction.
Note: pay extra attention to hoses with large movements - Check all the hydraulic hose connections for signs of leakages
- Remove any packaging material in and around the LFU.

Shaded hoses - hoses with large movementsUnshaded hoses - hoses with small movements
- Hydraulic hose
- Clamp
- Crimp shell
Accumulator Unit - Check Pressure
| Equipment Status | Program Step |
- Make sure that the LFU is free from loose or blocking objects.
- Check and if necessary set the hydraulic pressure and the air pressure for the accumulator, see Procedures Hydraulic Accumulator Pressure - Setand Pneumatic Pressures LFU - Set. Make sure that the non return valve is working properly, see Procedure Pneumatic Pressures LFU - Set.
- Check the movement of the spacer, see Procedure Pressing Unit - Check Spacer and Cylinder.
- Check, and if necessary, set the belt tension for the drive tool, see Procedure Drive Tool - Set Belt Tension.
- Check, and if necessary, set the belt tension for the motor unit, see Procedure Motor Unit - Set Belt Tension.
- Check the accumulator for leakage from the leakage detection hole, see Procedure Valve Ramp Unit - Check. Any air or oil leakage indicates that the sealings are worn out. If necessary, replace the accumulator according to Procedure Accumulator Unit - Change.
- Change the directional valve, see Procedure Directional Valve - Change.
- Bleed the system, see Procedure Hydraulic System LFU - Bleed.
- Check the cylinder, see Procedure Vertical Cylinder - Check.
Vertical Cylinder - Check
| Equipment Status | Program Step |
| Special Equipment | Pressure gauge, TP No. 2677917 |
- Close the external tools and step up to step Horizontal Force, see Procedure LFU Remote Control - Handle.
- Connect a Pressure gauge, with a range from 0 to 25 bar, to the Test connection on the Accumulator.
- Step the machine up to step Tightness.
- Check the oil pressure on the manometer. If the pressure increases 5 bar during 1 minute measuring time, there is a internal leakage in the Vertical cylinder. Change the cylinders, see Procedure Guide Hot Channel - Change Vertical Cylinder.

- Pressure gauge
- Test connection
- Accumulator
- Vertical cylinder
Accumulator Unit - Check Pressure Guard via Inlet Module
| Equipment Status | Program Step |
| Special Equipment | Heat-resistant protective gloves TP No. 90303-0012 Pressure gauge, TP No. 2677917 |
Hot surfacesThe hot channel and the extruder can be hot.Risk of burn.
- Set the hydraulic accumulator pressure. See Hydraulic Accumulator Pressure - Set on page Hydraulic Accumulator Pressure - Set.
- Open the Connection box.
- Turn the pressure regulator on the Recharging accumulator valve to increase the pressure. Make sure that the Status LED goes off when the pressure exceeds 8 bar and reduce the pressure to check that the status LED goes on when the pressure is between 7.5 and 5 bar.
- Set the recharge pressure to the correct value according to the table in procedure Settings and Forms LFU on page Settings and Forms LFU.

- Connection box
- Status LED
- Digital input PTS sink
- Recharging accumulator valve
Flow Restrictor - Check
| Equipment Status | Program Step |
| Special Equipment | Allen key |
- Dismantle the Accumulator
- Dismantle the Plug
Risk of damage to the equipmentBe careful not to drop the
Flow restrictor into the hydraulic block.The
Flow restrictor can fall into the hydraulic block and cause damage.
Dismantle the Flow restrictor with an Allen key- Check the Flow restrictor and clean it with compressed air.
- Assemble in the reverse order.

- Accumulator
- Plug
- Flow restrictor
Hydraulic Accumulator Pressure - Set
| Equipment Status | Program Step |
| Special Equipment | Heat-resistant protective gloves TP No. 90303-0012 Protective goggles TP No. 90303-0011 Pressure gauge, TP No. 2677917-0100 |
Handle Remote ControlInstruction regarding handle of the remote control and recharging accumulator, see Procedure LFU Remote Control - Handle.Risk of crushing and cutting.Enclose the area around the LFU and make sure that no unauthorized personnel can come in contact with the LFU.The movement in the LFU can cause injuries.
Hot surfacesThe hot channel and the extruder can be hot.Risk of burn.
- Connect a Pressure gauge which can take 0 to 2.5 MPa (0 to 25 Bar) to the Test connection.
- Activate step 1 (Hydraulic high Pressure) with the remote control.
Risk of damage to the equipment.Make sure that the mandrels are in a position where they cannot collide with the raising external tools.If the mandrels are positioned in the wrong direction when the recharging accumulator valve (2) is activated, the mandrels and the external tools can collide.
Activate step 2 (Locking scissors) and close tools with the Valve, recharging accumulator (S1/A30K1223, S2/A30K2223) and check the pressure on the pressure gauge.- If necessary, adjust hydraulic pressure with Reduction valve to 1.3 ±0.02 MPa (13 ±0.2 bar)Note: During adjusting, hold the Valve, recharging accumulator (S1/A30K1223, S2/A30K2223) pressed.Note: The pressure should be maintained during every cycle. If the pressure is not received, the accumulator check-valve can be broken. See procedure on page .

- Pressure gauge
- Valve, recharging accumulator (S1/A30K1223, S2/A30K2223)
- Reduction valve
- Test connection
Injection Pressure - Set
| Equipment Status | Program Step Heating |
| Special Equipment | Heat-resistant protective gloves TP No. 90303-0012 Protective goggles TP No. 90303-0011 |
The Valve, injection cylinder (S1/A30K1227, S2/A30K2227) being checked does not need to be activated. The measurements are made before the valves.Handle Remote ControlInstruction regarding handle of the remote control and recharging accumulator, see Procedure LFU Remote Control - Handle.Risk of crushing and cutting.Enclose the area around the LFU and make sure that no unauthorised personnel can come in contact with the LFU.The movement in the LFU can cause injuries.
Hot surfacesThe hot channel and the extruder can be hot.Risk of burn.
Oil under pressureUse protective goggles when working near and around the LFU unit. Also check the condition of the hydraulic hoses and connections before setting the machine into service mode. If necessary, change the hoses.Risk of eye injury.
- Activate step 1 (Hydraulic high Pressure) with the remote control.
- Check the injection pressure at the Test point.For the injection pressure for current lid, see Hydraulic and Pneumatic Pressures LFU - Record.
- If necessary, set the injection pressure on the Reduction valve..

- Valve, injection cylinder (S1/A30K1227, S2/A30K2227)
- Reduction valve.
- Test point
Horizontal Force Pressure - Set
| Equipment Status | Program Step |
| Special Equipment | Heat-resistant protective gloves TP No. 90303-0012 Protective goggle TP No. 90303-0011 |
Risk of crushing and cutting.Enclose the area around the LFU and make sure that no unauthorized personnel can come in contact with the LFU.The movement in the LFU can cause injuries.
Hot surfacesThe hot channel and the extruder can be hot.Risk of burn.
Oil under pressureUse protective goggles when working near and around the LFU unit. Also check the condition of the hydraulic hoses and connections before setting the machine into service mode. If necessary, change the hoses.Risk of eye injury.
The Valve, horizontal cylinder (S1/A30K1229, S2/A30K2229) do not need to be activated. The measurements are made before the valves.- Activate step 1 Hydraulic high Pressure with the remote control, see LFU Remote Control - Handle.
- Check the horizontal force pressure at the Test point of the related horizontal cylinder valve (2).
- If necessary, set the pressure on the Reduction valve:
- 8.0 MPa (80 bar)
- with CAU: 9.0 MPa (90 bar)

- Valve, horizontal cylinder (S1/A30K1229, S2/A30K2229)
- Reduction valve
- Test point
Tightness Pressure - Set
| Equipment Status | Program Step |
See instructions in LFU - Basic Set.Pressing Pressure - Set
| Equipment Status | Program Step |
See instructions in LFU - Basic Set for setting the pressing pressure.Accumulator Unit - Change
| Equipment Status | Program Step |
| Special Equipment | Spanner, 19 and 41mm Punching device (width 20-23 mm, height 200 mm, recommended to use hard plastic in one end). |
- Remove the Non return valve (19 mm), use a spanner, 19mm.Note: Take care of the Sealing.
- Remove the Accumulator unit by loosening the Nipple (32 mm), use a spanner, 41mm.
- Change the Accumulator unit and assemble it on the LFU in the reverse order.
- Set the air pressure, see Procedure Pneumatic Pressures LFU - Set.

- Accumulator unit
- Non return valve (19 mm)
- Sealing
- Nipple (32 mm)
Directional Valve - Change
| Equipment Status | Program Step |
| Consumables | Hydraulic oil |

- Valve, horizontal cylinder (S1/A30K1229, S2/A30K2229)
- Valve, reference stop cylinder (S1/A30K1225, S2/A30K2225)
- Valve, distance cylinder (S1/A30K1228, S2/A30K2228)
- Valve, tightness cylinder (S1/A30K1226, S2/A30K2226
- Valve, recharging accumulator (S1/A30K1223, S2/A30K2223)
- Valve, pressing cylinder (S1/A30K1222, S2/A30K2222)
- Disconnect the Hydraulic hoses.
- Clean the area around the Directional valve.
- Disconnect the Connector from the Directional valve.
- Remove the Directional valve.

- Hydraulic hoses
- Directional valve
- Connector
- Check all the Sealing ring and the Support ring on the removed Directional valve to make sure that they are whole. If any of the rings are broken there can be remains of them in the valve cavity of the block.
- If necessary, remove any remnants from the rings from the valve cavity.
- Lubricate the Threads, Sealing ring and the Support ring of the new directional valve (1) with hydraulic oil.
- Carefully install the new directional valve (2) and tighten it to the correct torque according to Hydraulic System LFU - Tightening Torques.
- Connect the Connector to the Directional valve.

- Sealing ring
- Support ring
- Threads
Directional Valve - Change
| Equipment Status | Program Step AIR ON |
| Consumables | Hydraulic oil |

- Valve, injection cylinder (S1/A30K1227, S2/A30K2227)
- Disconnect the Hydraulic hoses.

- Hydraulic hoses
- Clean the area around the Directional valve.
- Disconnect the Connector from the Directional valve.
- Remove the Directional valve.

- Directional valve
- Connector
- Check all the Sealing ring and the Support ring on the removed Directional valveto make sure that they are whole. If any of the rings are broken, there can be remains of them in the valve cavity of the block.
- If necessary, remove any remnants from the rings from the valve cavity.
- Lubricate the Threads, the Sealing ring, and the Support ring of the new directional valve (1) with hydraulic oil.
- Carefully install the new Directional valve and tighten it to the correct torque according to 3.14.3-20 Hydraulic System LFU - Tightening Torques.
- Connect the Connector to the Directional valve.

- Sealing ring
- Support ring
- Threads
Directional Valve - Change
| Equipment Status | Program Step AIR ON |
- Disconnect the Hydraulic hoses.
- Clean the area around the Directional valve to avoid contamination of the hydraulic system.
- Disconnect the Connector from the Directional valve.

- Hydraulic hoses
- Directional valve
- Connector
- Remove the Screw.
- Remove the Directional valve.
- Make sure that the face of the new directional valve is as clean as possible.
- Make sure that the face of the Lid is as clean as possible.
- Make sure that all the o-rings on the Lid are in place.
- Carefully install the new directional valve.
- Lubricate the threads of the Screw.
- Tighten the Screw to the correct torque according to 3.14.3-21 Hydraulic System LFU - Tightening Torques
- Connect the Connector.
- Connect the Hydraulic hoses.

- Directional valve
- Screw
- Lid
Hydraulic System LFU - Bleed
| Equipment Status | Program Step HEATING |
| Special Equipment | Heat-resistant protective gloves TP No. 90303-0012 Protective goggle TP No. 90303-0011 A transparent bottle with cap and hose |
Risk of crushing and cutting.Be careful when working near the moving parts. It is recommended to use trained personnel when working with the LFU unit in service position.The machine contains moving parts that can crush.
Hot surfacesThe hot channel and the extruder can be hot.Risk of burn.
Oil under pressureUse protective goggles when working near and around the
LFU unit. Also check the condition of the hydraulic hoses and connections before setting the machine into service mode. If necessary, change the hoses. See Procedure on page
Hydraulic System LFU - Change Hydraulic Hoses. Risk of eye injury.
Reference Cylinders
- Open the doors for the LFU.
- Start up the hydraulic unit with low pressure. See Procedure LFU Remote Control - Handle.
- Apply a suitable Hose through the Cap on a Transparent Bottle.Note: The hose must fit the Ventilating Nipples.
- Fit the Hose on the Ventilating Nipples and open the Ventilating Nipples.
- Make sure to completely empty the Reference Cylinder from air, by activating and deactivating the Reference Cylinder Valve manually on the hydraulic block, a couple of times.
- Check the evacuating oil and make sure that it is free from air.

- Hose
- Cap
- Transparent Bottle
- Ventilating Nipples
- Reference Cylinder
- Reference Cylinder Valve
- Bleed button
- Window “Service Functions”
- When the oil is free from air, tighten the Ventilating Nipples.
- Push the Bleed button on the LFU Window “Service Functions” window, and open the Ventilating Nipples to check for air in the oil.Note: When bleed is pushed the machine will apply low hydraulic pressure on the following parts: Horizontal Cylinders, the Reference Cylinder, and the Injection Cylinders.
- Check the evacuating oil and make sure that it is free from air
- When the oil is free from air, tighten the Ventilating Nipples.
- Deactivate the bleeding function by pushing the Bleed button on the Window “Service Functions” window.
- Leave the Window “Service Functions” window by deactivating the service key.Note: Repeat steps to with some runtime in between (6-20h), until the oil is completely free from air. This due to that the Reference Cylinder is the highest point in the hydraulic system.Note: If bleedings are required frequently, the reason can be air leakage through an invisible hole in the cylinder hydraulic hose. Check or change the affected hydraulic hose and perform a new bleeding.

- Hose
- Cap
- Transparent Bottle
- Ventilating Nipples
- Reference Cylinder
- Reference Cylinder Valve
- Bleed button
- Window “Service Functions”
Injection and Horizontal Cylinders
- Open the doors for the LFU.
- Start up the hydraulic unit with low pressure. See Procedure LFU Remote Control - Handle.
- Push the Bleed button on the LFU Window “Service Functions” window.The machine will now apply low hydraulic pressure on the following parts:

- Bleed button
- Window “Service Functions”
- Apply a suitable Hose through the Cap on a Transparent Bottle.Note: The hose must fit the Ventilating Nipples and the Ventilating Nipples.
- Fit the Hose on the Ventilating Nipples on the Horizontal Cylinders, or the Ventilating Nipples on the Injection Cylinders, depending on which cylinder that needs to be bled.
- Check the evacuating oil and make sure that it is free from air.
- When the oil is free from air, tighten the Ventilating Nipples, or the Ventilating Nipples.
- Deactivate the bleeding function by pushing the Bleed button on the Window “Service Functions” window.
- Leave the Window “Service Functions” window by deactivating the service key.Note: If bleedings are required frequently, the reason can be air leakage through an invisible hole in the cylinder hydraulic hose. Check or change the affected hydraulic hose and perform a new bleeding.

- Hose
- Cap
- Transparent Bottle
- Ventilating Nipples
- Horizontal Cylinders
- Ventilating Nipples
- Injection Cylinders
Hydraulic System LFU - Tightening Torques
| Equipment Status | Program Step step zero |
Tightening Torques - Valve Ramp
| Torque X (Nm) | Torque Y (Nm) |
| A (3/4") | 320 | 135 |
Tightening Torques - Accumulator Unit
| A | B | C | D | E | F | G | H | I | J | K | L | M | N |
| Torque (Nm) | 45 | 79 | 15 | 20 | 70 | 10 | 33 | 100 | 180 | 3 | 44 | 50 | 5-7 | 22 |
Tightening Torques - Pipe Work
| Torque X (Nm) | Torque Y (Nm) |
| B (1/2") | 160 | 76 |
| C (1/4") | 50 | 30 |
| D (3/8") | 80 | 76 |
Description
A pneumatic diagram for the LFU can be found in the laminated documents provided with the machine.
The illustration shows the pneumatic system for S1. S2 is mirror-inverted to S1.
- Recharging accumulator
- Plastic accumulator
- Dosing unit
- Locking Scissors
- Mandrels
- Needle cylinder
- LFU Valve
Pneumatic System LFU - Check
| Equipment Status | Program Step |
See the pneumatic system Description.- Check so that there are no damaged pneumatic hoses.
- Check all hose connections.
- Check for air leaks.
Risk of fire.Make sure that no packaging materials or hoses touch these hot surfaces.There are several hot surfaces on the LFU that can cause fires.
Check the hoses and make sure that they do not touch any of the hot surfaces. Make sure that all the hoses are installed and routed in a similar way to how they were when the LFU was delivered. Take the movement of the mechanism into consideration.- Remove any packaging material in and around the LFU.
Pneumatic Pressures LFU - Set
| Equipment Status | Program Step |
| Special Equipment | Protective goggles TP No. 90303-0011 |
Set Air Pressure for Hydraulic and Plastic Accumulator
This chapter contains information about three different variants: Festo, Mecman, and Updated Injection Cylinder. Make sure to use the correct instruction.Valid for: FestoBecause the hydraulic and plastic accumulator are connected to the same hose, they affect each other during the setting.To compensate for this fact, do as follows:- Check and set the air pressure on Side 1 and Side 2 according to the following instructions.

- Side 1
- Side 2
- For each side, check and set the air pressure for the plastic accumulator on the Manometer by turning the Knob.The plastic accumulator air pressure is different depending on the opening. See Hydraulic and Pneumatic Pressures LFU - Record.
- Locate A30K1232 (S1), A30K2232 (S2) on the Pneumatic unit.

- Manometer
- Knob
- Pneumatic unit
- Remove the two Screw.
- Remove the Cover.

- Screw
- Cover
- Turn the Solenoid valve to the right to force the pump.

- Solenoid valve
- Check and set the air pressure for the Hydraulic accumulator on the Manometer by turning the Knob.For the hydraulic accumulator air pressure, see Hydraulic and Pneumatic Pressures LFU - Record.
- Check/set the pressure according to item Reference and Reference one more time.If the pressure is set too high on the Hydraulic accumulator (not possible to turn back), release the pressure by loosening the Non-return valve.
- Release A30K1232 (S1) and A30K2232 (S2).

- Hydraulic accumulator
- Non-return valve
- Manometer
- Knob
- Turn the Solenoid valve to the left to stop forcing the valve.
- Install the Cover.

- Cover
- Solenoid valve
Valid for: MecmanValid for: Hot Channel Piston Version Without CoolingBecause the hydraulic and plastic accumulator are connected to the same hose, they affect each other during the setting.To compensate for this fact, do as follows:- Check and set the air pressure for the plastic accumulator on the Manometer by turning the Knob.The plastic accumulator air pressure is different depending on the opening. See Hydraulic and Pneumatic Pressures LFU - Record.
- Press and keep pressed A30K1232 (S1) and A30K2232 (S2) on the Pneumatic unit.

- Manometer
- Knob
- Pneumatic unit
- Check and set the air pressure for the Hydraulic accumulator on the Manometer by turning Knob.For the hydraulic accumulator air pressure, see Hydraulic and Pneumatic Pressures LFU - Record.
- Check and set the pressure according to item Reference and Reference one more time.If the pressure is set too high on the Hydraulic accumulator (not possible to turn back), release the pressure by loosening the Non-return valve.
- Release A30K1232 (S1) and A30K2232 (S2).

- Hydraulic accumulator
- Non-return valve
- Manometer
- Knob
Valid for: MecmanValid for: Hot Channel Piston Version Without CoolingBecause the hydraulic and plastic accumulator are connected to the same hose, they affect each other during the setting.To compensate for this fact, do as follows:- Check and set the air pressure on Side 1 and Side 2 according to the following instructions.
- Press and hold A30K1232 (S1), A30K2232 (S2) on Side 2.

- Side 1
- Side 2
- For each side, check and set the air pressure for the plastic accumulator on the Manometer by turning the Knob.The plastic accumulator air pressure is different depending on the opening. See Hydraulic and Pneumatic Pressures LFU - Record.
- Press and hold A30K1232 (S1) and A30K2232 (S2) on the Pneumatic unit.

- Manometer
- Knob
- Pneumatic unit
- Check and set the air pressure for the Hydraulic accumulator on the Manometer, by turning the Knob.For the hydraulic accumulator air pressure, see Hydraulic and Pneumatic Pressures LFU - Record.
- Check/set the pressure according to item Reference to Reference one more time.If the pressure is set too high on the Hydraulic accumulator (not possible to turn back), release pressure by loosening the Non-return valve.
- Release A30K1232 (S1) and A30K2232 (S2).

- Hydraulic accumulator
- Non-return valve
- Manometer
- Knob
Basic Set Lid Blowing LFU
Valid for: Festo- Locate A30K1231 (S1), A30K2231 (S2) on the Pneumatic unit.
- Remove the two Screw.
- Remove the Cover.

- Pneumatic unit
- Screw
- Cover
- Turn the Solenoid valve to the right to force the valve.

- Solenoid valve
- Release the regulator by pulling out the Knob.
- Press the Valve and check the pressure on the Manometer.
- Adjust the lid blowing pressure with the Knob to 0.01 to 0.2 MPa (0.1 to 2Bar)Note: Keep the Valve pressed during the adjustment.

- Pneumatic unit
- Knob
- Valve
- Manometer
- Turn the Solenoid valve to the left to stop forcing the valve.
- Install the Cover.
- Do the final adjustment for the lid blow during production. See procedure Reference.

- Cover
- Solenoid valve
Valid for: Mecman- Press and hold A30K1231 (S1) and A30K2231 (S2) on the Pneumatic unit.
- Release the regulator by pulling out the Knob.
- Press the Valve and check the pressure on the Manometer.
- Adjust the lid blowing pressure with the Knob to 0.01 to 0.2 MPa (0.1 to 2Bar)Note: Keep the Valve pressed during the adjustment.
- Do the final adjustment for the lid blow during production. See the following instructions.

- Pneumatic unit
- Knob
- Valve
- Manometer
Set Lid Blowing during Production
Valid for: Festo and MecmanRisk of crushing and cutting.Make sure that all settings are performed with closed doors.The movement in the LFU can cause injuries.
Step the machine up to PRODUCTION.- Observe the lid shape during production. Too low pressure causes a Sucked in lid while too high pressure causes a Blown open membrane.
- Adjust the lid blowing pressure and press the Knob to secure and lock.

- Knob
- Sucked in lid
- Blown open membrane
Pneumatic System LFU - Change Non Return Valve
| Equipment Status | Program Step |
- Change the Non Return Valve and the Washer.

- Non Return Valve
- Washer
Frame - Change Sheet and Spacer
| Equipment Status | Program Step zero |
| Special Equipment | Vice |
| Consumables | Loctite 243 TP No. 344431-0000 |
- Remove the Screw.
- Valid for: Barrier nut and flange nutThe Spacer, the Spring, the Barrier nut, and the Flange nut will come down with the Screw.
- In a vise, fasten the Spacer and remove the Barrier nut and the Flange nut if the parts are reusable.
- Valid for: Plate and nutThe Spacer, the Spring, the Nut, and the Plate will come down with the Screw.
- In a vice, fasten the Spacer and remove the Nut and the Plate if the parts are reusable.
- Remove the Screws.
- Change the Sheet and the Spacer.
- Assemble in reverse order.
- Use Loctite on the Screw.

- Screw
- Spacer
- Spring
- Barrier nut
- Flange nut
- Nut
- Plate
- Screws
- Sheet
- Valid for: Barrier nut and flange nutWhen assembling the Barrier nut and the Flange nut, make sure that there is a distance A between the parts.
- Tighten the Screw to 10 Nm to 12 Nm.
- Check the gap between bearing halves and mandrel shaft. See Procedure Section Check the Gap between Bearing Halves and Mandrel Shaft in Procedure LFU - Basic Set.
Valid for: Barrier nut and flange nutA = 1-3 mm
- Barrier nut
- Flange nut
- Screw
- Valid for: Plate and nutAssemble the Nut and the Plate.Tighten the Nut to 100 Nm.
- Check the gap between bearing halves and mandrel shaft. See Procedure Section Check the Gap between Bearing Halves and Mandrel Shaft in Procedure LFU - Basic Set.
Valid for: Plate and nut
- Nut
- Plate
Settings and Forms LFU
In the coming tables there are inserted blank squares, the meaning with these is to use them during settings/checks. Make a copy of this chapter and use it as “work paper”. Temperatures LFU - Record
The tables show default values for the setting of the temperatures that relate to opening type and position in the LFU.Note: The temperature values are specified using the unit of degrees Celsius (°C).Note: If necessary, fine-tune the set default values. | Temperature (°C) |
| Opening | Lid Material | Injection Unit zone 1 | Injection Unit zone 2 | Injection Unit zone 3 | Plastic accumulator | Plastic hoses | Hot channels |
| Base Eifel C38 | PE06 | 140 | 180 | 220 | 220 | 220 | 220 |
| Base Eifel O38 | PE06 | 140 | 180 | 220 | 220 | 220 | 220 |
| Base Goldeck S38 PB | PE04 | 110 | 140 | 160 | 190 | 200 | 205 |
| Base Katla H38 BT | PE04 | 110 | 140 | 160 | 185 | 185 | 185 |
| Base Katla H38 PB | PE04 | 110 | 140 | 160 | 190 | 200 | 205 |
| Base Katla H38 SP | PE04 | 110 | 140 | 160 | 190 | 200 | 205 |
| Base Katla S38 BT | PE04 | 110 | 140 | 160 | 185 | 185 | 185 |
| Base Katla S38 PB | PE04 | 110 | 140 | 160 | 190 | 200 | 205 |
| Base Katla S38 SP | PE04 | 110 | 140 | 160 | 190 | 200 | 205 |
| Base Orinoco S38 BT | PE04 | 110 | 140 | 160 | 185 | 185 | 185 |
| Base Orinoco S38 PB | PE04 | 110 | 140 | 160 | 190 | 200 | 205 |
| Temperature (°C) |
| Opening | Lid Material | Injection Unit zone 1 | Injection Unit zone 2 | Injection Unit zone 3 | Plastic accumulator | Plastic hoses | Hot channels |
| Midi Eifel C38 | PE06 | 140 | 180 | 220 | 220 | 220 | 220 |
| Midi Eifel O38 | PE06 | 140 | 180 | 220 | 220 | 220 | 220 |
| Midi Huron | PE04/C01 | 110 | 140 | 160 | 190 | 200 | 205 |
| Midi Idum O38 | PE06 | 140 | 180 | 220 | 220 | 220 | 220 |
| Midi Idum C38 | PE06 | 140 | 180 | 220 | 220 | 220 | 220 |
| Midi Idum A38 | PE06 | 140 | 180 | 220 | 220 | 220 | 220 |
| Midi Katla H38 BT | PE04 | 110 | 140 | 160 | 185 | 185 | 185 |
| Midi Katla H38 PB | PE04 | 110 | 140 | 160 | 190 | 200 | 205 |
| Midi Katla H38 SP | PE04 | 110 | 140 | 160 | 190 | 200 | 205 |
| Midi Katla S38 BT | PE04 | 110 | 140 | 160 | 185 | 185 | 185 |
| Midi Katla S38 PB | PE04 | 110 | 140 | 160 | 190 | 200 | 205 |
| Midi Katla S38 SP | PE04 | 110 | 140 | 160 | 190 | 200 | 205 |
| Temperature (°C) |
| Opening | Lid Material | Injection Unit zone 1 | Injection Unit zone 2 | Injection Unit zone 3 | Plastic accumulator | Plastic hoses | Hot channels |
| Mini Eifel C38 | PE06 | 140 | 180 | 220 | 220 | 220 | 220 |
| Mini Eifel O38 | PE06 | 140 | 180 | 220 | 220 | 220 | 220 |
| MiniV Nallo A38 | PE06 | 140 | 180 | 220 | 220 | 220 | 220 |
| MiniV Nallo C38 | PE06 | 140 | 180 | 220 | 220 | 220 | 220 |
| MiniV Nallo O38 | PE06 | 140 | 180 | 220 | 220 | 220 | 220 |
| Mini Katla H38 SP | PE04 | 110 | 140 | 160 | 190 | 200 | 205 |
| Mini Katla S30 BT | PE04 | 110 | 140 | 160 | 185 | 185 | 185 |
| Mini Katla S30 PB | PE04 | 110 | 140 | 160 | 190 | 200 | 205 |
| Mini Katla S30 SP | PE04 | 110 | 140 | 160 | 190 | 200 | 205 |
| Mini Katla S38 BT | PE04 | 110 | 140 | 160 | 185 | 185 | 185 |
| Mini Saroma V1 | PE04 | 110 | 140 | 160 | 190 | 200 | 200 |
| Mini Saroma V2 Tamper | PE04 | 110 | 140 | 160 | 165 | 165 | 165 |
| Mini Taishan A38 | PE06 | 140 | 180 | 220 | 220 | 220 | 220 |
| Micro Bothnia S30 BT | PE04 | 110 | 140 | 160 | 185 | 185 | 185 |
| Micro Lokka | PE04 | 110 | 165 | 185 | 185 | 185 | 185 |
ResultsRecord your actual values in the table. | Temperature (°C) |
| Opening | Lid Material | Injection Unit zone 1 | Injection Unit zone 2 | Injection Unit zone 3 | Plastic accumulator | Plastic hoses | Hot channels |
| S1: | | | | | | | |
| S2: | | | | | | | |
| Check/Settings performed, date: | Signature: |
| |
| |
Hydraulic Unit Pressures
| Check/Settings performed, date: | Signature: |
| |
| |
Hydraulic and Pneumatic Pressures LFU - Record
Included in MM and UP for Conv. Kit OpeningsThe tables show default values for setting the hydraulic and pneumatic pressures that relate to opening type and position in the LFU.Note: The pressure values are specified using the unit of bar (1 bar≡100 000 Pa). | Pneumatic Pressure (bar) | Hydraulic Pressure (bar) |
| Opening | Hydraulic accumulator1 | Plastic accumulator1 | Pressing2 | Tightness3 | Recharging accumulator4 | Horizontal force5 | Injection6 |
| Base Eifel C38 | 2.9 ±0.1 | 5.0 | 50 | 18 | 13 ±0.2 | 90 | 140+10/-0 |
| Base Eifel O38 | 2.9 ±0.1 | 5.0 | 50 | 18 | 13 ±0.2 | 90 | 140+10/-0 |
| Base Goldeck S38 PB | 2.9 ±0.1 | 3.5 | 60 | 18 | 13 ±0.2 | 80 | 110 |
| Base Katla H38 BT | 2.9 ±0.1 | 3.5 | 70 | 18 | 13 ±0.2 | 80 | 110 |
| Base Katla H38 PB | 2.9 ±0.1 | 3.5 | 70 | 18 | 13 ±0.2 | 80 | 110 |
| Base Katla H38 SP | 2.9 ±0.1 | 3.5 | 70 | 18 | 13 ±0.2 | 80 | 110 |
| Base Katla S38 BT | 2.9 ±0.1 | 3.5 | 70 | 18 | 13 ±0.2 | 80 | 110 |
| Base Katla S38 PB | 2.9 ±0.1 | 3.5 | 70 | 18 | 13 ±0.2 | 80 | 110 |
| Base Katla S38 SP | 2.9 ±0.1 | 3.5 | 70 | 18 | 13 ±0.2 | 80 | 110 |
| Base Orinoco S38 BT | 2.9 ±0.1 | 3.5 | 55 | 18 | 13 ±0.2 | 80 | 110 |
| Base Orinoco S38 PB | 2.9 ±0.1 | 3.5 | 55 | 18 | 13 ±0.2 | 80 | 110 |
| Midi Eifel C38 | 2.9 ±0.1 | 5.0 | 35 | 18 | 13 ±0.2 | 90 | 140+10/-0 |
| Midi Eifel O38 | 2.9 ±0.1 | 5.0 | 35 | 18 | 13 ±0.2 | 90 | 140+10/-0 |
| Midi Idum O38 | 2.9 ±0.1 | 5.0 | 35 | 18 | 13 ±0.2 | 90 | 140+10/-0 |
| Midi Idum C38 | 2.9 ±0.1 | 5.0 | 35 | 18 | 13 ±0.2 | 90 | 140+10/-0 |
| Midi Idum A38 | 2.9 ±0.1 | 4.5 | 55 | 18 | 13 ±0.2 | 90 | 120+10/-0 |
| Midi Huron | 2.9 ±0.1 | 3.5 | 40 | 18 | 13 ±0.2 | 80 | 110 |
| Midi Katla H38 BT | 2.9 ±0.1 | 3.5 | 40 | 18 | 13 ±0.2 | 80 | 110 |
| Midi Katla H38 PB | 2.9 ±0.1 | 3.5 | 40 | 18 | 13 ±0.2 | 80 | 110 |
| Midi Katla H38 SP | 2.9 ±0.1 | 3.5 | 40 | 18 | 13 ±0.2 | 80 | 110 |
| Midi Katla S38 BT | 2.9 ±0.1 | 3.5 | 40 | 18 | 13 ±0.2 | 80 | 110 |
| Midi Katla S38 PB | 2.9 ±0.1 | 3.5 | 40 | 18 | 13 ±0.2 | 80 | 110 |
| Midi Katla S38 SP | 2.9 ±0.1 | 3.5 | 40 | 18 | 13 ±0.2 | 80 | 110 |
| Pneumatic Pressure (bar) | Hydraulic Pressure (bar) |
| Opening | Hydraulic accumulator1 | Plastic accumulator1 | Pressing2 | Tightness3 | Recharging accumulator4 | Horizontal force5 | Injection6 |
| Mini Eifel C38 | 2.9 ±0.1 | 5.0 | 30 | 18 | 13 ±0.2 | 90 | 140+10/-0 |
| Mini Eifel O38 | 2.9 ±0.1 | 5.0 | 30 | 18 | 13 ±0.2 | 90 | 140+10/-0 |
| MiniV Nallo A38 | 2.9 ±0.1 | 5.0 | 35 | 18 | 13 ±0.2 | 90 | 120+10/-0 |
| MiniV Nallo C38 | 2.9 ±0.1 | 5.0 | 30 | 18 | 13 ±0.2 | 90 | 140+10/-0 |
| MiniV Nallo O38 | 2.9 ±0.1 | 5.0 | 30 | 18 | 13 ±0.2 | 90 | 140+10/-0 |
| Mini Katla H38 PB | 2.9 ±0.1 | 3.5 | 30 | 18 | 13 ±0.2 | 80 | 110 |
| Mini Katla H38 SP | 2.9 ±0.1 | 3.5 | 30 | 18 | 13 ±0.2 | 80 | 110 |
| Mini Katla S30 BT | 2.9 ±0.1 | 3.5 | 30 | 18 | 13 ±0.2 | 80 | 110 |
| Mini Katla S30 PB | 2.9 ±0.1 | 3.5 | 30 | 18 | 13 ±0.2 | 80 | 110 |
| Mini Katla S30 SP | 2.9 ±0.1 | 3.5 | 30 | 18 | 13 ±0.2 | 80 | 110 |
| Mini Katla S38 BT | 2.9 ±0.1 | 3.5 | 30 | 18 | 13 ±0.2 | 80 | 110 |
| Mini Saroma | 2.9 ±0.1 | 3.5 | 40 | 18 | 13 ±0.2 | 80 | 110 |
| Mini Taishan A38 | 2.9 ±0.1 | 4.5 | 40 | 18 | 13 ±0.2 | 90 | 120 |
| Micro Bothnia S30 BT | 2.9 ±0.1 | 3.5 | 30 | 18 | 13 ±0.2 | 80 | 110 |
| Micro Lokka | 2.9 ±0.1 | 3.5 | 30 | 18 | 13 ±0.2 | 80 | 110 |
ResultsRecord the actual values in the table below. | Pneumatic Pressure(bar) | Hydraulic Pressure(bar) |
| Opening | Hydraulic acc.1 | Plastic acc.1 | Pressing2 | Tightness3 | Recharg acc.4 | Horizontal force5 | Injection6 |
| S1: | | | | | | | |
| S2: | | | | | | | |
| Check/Settings performed, date: | Signature: |
| |
| |
Cooling Water Flow LFU - Record
| Deionized Cooling Water |
| Item | Setting value | Result Side 1 | Result Side 2 |
| Internal tools | 16 litres / minute | | |
| External tools (4 pair) | 4 litres / minute | | |
| Glycol Cooling Water |
| Item | Setting value | Result Side 1 | Result Side 2 |
| Cooling Water System LFU | 3-4 litres / minute | | |
| Hot Channel Cylinder (Valid for With Cooling) | 4-6 litres/minute | | |
| Check/Settings performed, date: | Signature: |
| | |
| | |
Cooling Water Temperatures LFU - Record
| Item | Setting value | Result Side 1 | Result Side 2 |
| Deionized Cooling Water | 25°C | | |
| Glycol Cooling Water (used in Cooling Water System LFU and cooling ring system) | 25°C | | |
| Check/Settings performed, date: | Signature: |
| | |
| | |
Tools LFU
| Item | Setting value (mm) | Result Side 1 | Result Side 2 | MM reference |
| Distance between external tools and reference stop | 0.05 +0.05/-0 | | | LFU - Basic Set |
| Distance and gap between external tools and hot channel | 0.40 +0.1/ -0 | | | LFU - Basic Set |
| Initial CavityBase Eifel O38/C38 with FIXED bushing | 0.85 ±0.05 | | | LFU - Basic Set |
| Initial CavityC38 with spring-loaded bushing, Template[1] | 1.1 ±0.05 | | | LFU - Basic Set |
| Initial Cavity(Other tools) | 0.90 ±0.05 | | | LFU - Basic Set |
| Tin solder | Min 0.70 | | | LFU - Basic Set |
| Bronze washer thickness | Min 4.9 | | | LFU - Basic Set |
| Difference between activating and deactivating the tightness for the outer and the middle bearing halves. | 0.2 +0.05/-0.00 | | | LFU - Basic Set |
| Check/Settings performed, date: | Signature: |
| |
| |
Basic Alignment LFU
Template for basic alignment measurement and calculation| Engraved value | A | B | C | D (front) |
| Upper | | | | |
| Lower | | | | |
First measurement | A upper | B upper | C upper | D (front) upper |
| Engraved value | N/A | | N/A | |
| Compensation | N/A | | N/A | |
| Measured | N/A | | N/A | |
| Compensated | N/A | | N/A | |
| A lower | B lower | C lower | D (front) lower |
| Engraved value | | | | |
| Compensation | | | | |
| Measured | | | | |
| Compensated | | | | |
First measurement calculationCompensated B upper - Compensated B lower = Result| Compensated B upper | Compensated B lower | Result | Tolerance | Pass/Fail |
| | | ±0.05 | |
Compensated A lower - Compensated C lower = Result| Compensated A lower | Compensated C lower | Result | Tolerance | Pass/Fail |
| | | ±0.05 | |
Compensated D upper - Compensated D lower = Result| Compensated D upper | Compensated D lower | Result | Tolerance | Pass/Fail |
| | | ±0.05 | |
Measurement after adjustment | A upper | B upper | C upper | D (front) upper |
| Engraved value | N/A | | N/A | |
| Compensation | N/A | | N/A | |
| Measured | N/A | | N/A | |
| Compensated | N/A | | N/A | |
| A lower | B lower | C lower | D (front) lower |
| Engraved value | | | | |
| Compensation | | | | |
| Measured | | | | |
| Compensated | | | | |
Calculation after adjustmentCompensated B upper - Compensated B lower = Result| Compensated B upper | Compensated B lower | Result | Tolerance | Pass/Fail |
| | | ±0.05 | |
Compensated A lower - Compensated C lower = Result| Compensated A lower | Compensated C lower | Result | Tolerance | Pass/Fail |
| | | ±0.05 | |
Compensated D upper - Compensated D lower = Result| Compensated D upper | Compensated D lower | Result | Tolerance | Pass/Fail |
| | | ±0.05 | |
1000 h Status Check of LFU
Machine No:.....................................Hour Meter Reading............................Side No:............................................Date:..................................................Sign:..........................| Unit | Measured detail | Range | Result |
| Hot channel | Check hot channel regarding melted plastic/dirt.Clean injection cylinder from plastic residue.See Procedure Hot Channel - Check. | OK | |
| External tools | Check for damage on the side against the hot channel.See Procedure External Tools - Check. | OK | |
| Internal tools | Check for damages.See Procedure Internal Tools - Check. | OK | |
| Basic Set | Check the Basic Settings of the LFU.See Procedure LFU - Basic Set. | | |
| Opening forceLid thicknessNeck thickness | Packages from all mandrels | See Procedure Tools - Check Lid. | |
| Nondestructive check:Appearance | Packages from all mandrels | See OM-PC. | |
| Other comments:Note: Put sleeves on the mandrels before applying “locking” to prevent damage of the tools. |
Test Form for Neck Thickness
Taishan| Machine No.: | Sampling Point:After the filling machine |
| Comments: |
| | | | | | | | | | | |
| Production Date and Time | Tool Identification No. | Mandrel No. | Neck Thickness (mm) |
| Measuring Spot | Average | Difference | |
| 1 | 2 | 3 | 4 | 5 | 6 | 1 to 4 | 2 to 5 | 3 to 6 |
| | S1:1/1 | | | | | | | | | | |
| S1:1/2 | | | | | | | | | | |
| S1:1/3 | | | | | | | | | | |
| S1:1/4 | | | | | | | | | | |
| S1:2/1 | | | | | | | | | | |
| S1:2/2 | | | | | | | | | | |
| S1:2/3 | | | | | | | | | | |
| S1:2/4 | | | | | | | | | | |
| | | | | | | | | | | | |
| Average: | | | | | | | | | | |
| | | | | | | | | | | | |
| | S2:1/1 | | | | | | | | | | |
| S2:1/2 | | | | | | | | | | |
| S2:1/3 | | | | | | | | | | |
| S2:1/4 | | | | | | | | | | |
| S2:2/1 | | | | | | | | | | |
| S2:2/2 | | | | | | | | | | |
| S2:2/3 | | | | | | | | | | |
| S2:2/4 | | | | | | | | | | |
| | | | | | | | | | | | |
| Average: | | | | | | | | | | |
Pneumatic Collector - Set
| Equipment Status | Air must be turn OFF.
|
- Slide the Pneumatic collector to the front end position.

- Pneumatic collector
- Put the Sensor screw in horizontal position to loosen the Sensor .

- Sensor screw
- Sensor
- Place the Sensor according to measurement A.
- Fine adjust by positioning the Sensor so that only the yellow LED shines.Note: If both the yellow LED and the orange LED shines, the Sensor is incorrectly positioned.
- Put the Sensor screw in vertical position to lock the position of the Sensor.

S1, A = 40 mm
S2, A = 120 mm
- Sensor screw
- Sensor
- Slide the Pneumatic collector to the rear end position.

- Pneumatic collector
- Put the Sensor screw in horizontal position to loosen the Sensor.

- Sensor screw
- Sensor
- Place the Sensor according to measurement B.
- Fine adjust by positioning the Sensor so that only the yellow LED shines.Note: If both the yellow LED and the orange LED shines, the Sensor is incorrectly positioned.
- Put the Sensor screw in vertical position to lock the position of the Sensor.

S1, B = 115 mm
S2, B = 30 mm
- Sensor screw
- Sensor
Sleeve Stop - Check Cylinder Sensor
| Equipment Status | Power must be turn ON.
|
- Check that the Sensor light is lit when the Stop Plate is in its Lower Position.
- Manually pull up the Stop Plate, and check that the Sensor light is turned off.
- Push down the Stop Plate until it reaches mechanical stop in it's Lower position.
- Check that the Sensor light is turned back on.

- Sensor light
- Stop Plate
Sleeve Stop - Set Cylinder Sensor
| Equipment Status | Power must be turn ON.
|
- Make sure that the Stop Plate is in it's Lower position.
- Move the Sensor downwards in the groove of the Cylinder, until the Sensor Light is lit.

- Stop Plate
- Sensor
- Cylinder
- Sensor Light
- Use a allen key and turn the Locking Screw to lock the position of the Sensor.
- Make sure that the Sensor Light is still lit.

- Sensor
- Sensor Light
- Locking Screw
Sleeve Stop - Adjustment
| Equipment Status | Power must be turn ON.
|
- Run two sleeves and stop the machine with the short stop button, when the two Sleeve have landed in the Magazine plate and the first index movement is finished.
- Turn the Magazine plate by hand and stop the two packages in top position.Note: Do not move the sleeves when turning the Magazine plate.
- Lift up the Stop Plate by hand and check the distance between the Stop Plate and the edge of the Sleeve.
- Set the distance A. Make sure to set the distance for both sleeves.

A= 1.5 ±0.5 mm
- Stop Plate
- Sleeve
- Magazine plate
Sleeve Stop - Secure Stop Plate
| Equipment Status | Program Step |
Remove Stop Plate- Pull the Knob to free the Stop Plate from the Sleeve Stop .
- Remove the Stop Plate according to the image below.

- Knob
- Stop Plate
- Sleeve Stop
Fasten Stop Plate- Pull the Knob to attach the Stop Plate in a downward angle (see image).
- Fasten the Stop Plate by releasing the Knob.
- Make sure that the edges of the Stop Plate are attached by the grooves(arrows) of the Sleeve Stop .
- Yank the Stop Plate to make sure that the it is properly secured to the Sleeve Stop.

- Knob
- Stop Plate
- Sleeve Stop
Sleeve Stop - Set Position
| Equipment Status | Power must be turn ON.
|
- Check and set LFU Stripper according to 3.2-2 LFU - Basic Set in the Maintenance Manual.
- Make sure to set the LFU stripper position according to 3.12.1-2 Guide Stripper - Set Position.
- Check the position of the CAU stripper according to 4.4.3-7 Drive Unit - Set Stop Plate .
- Loosen the Screw to set the distance A between the Stop Plate and the Magazine Plate.
- Tighten the Screw.

A = 11 ±0.5 mm
- Screw
- Stop Plate
- Magazine Plate
Sleeve Stop - Enable/Disable
| Equipment Status | Program Step Step zero |
| Special Equipment | Keyboard |
- Connect a Keyboard to the TPOP.
- Push F4 on the keyboard to open the
Technical Menu. - Press
Main.Note: If the screen below does not open, press anywhere on the screen and then press F4 again.
- Press Go to submenu.
- Select Sleeve stop installed to YES on affected machine side/sides.

- Sleeve stop installed
- Step the machine up to air on.
- Press the Manoeuvre window button, and then the CAU button.
- Press the Sleeve stop button to enable/disable the Sleeve stop function.Note: When Sleeve stop is disabled, there is a green indicator on the Sleeve stop button.
- Press Exit.

Manoeuvre window buttonCAU buttonSleeve stop buttonExit
Screw Cap Application Unit
Description
This chapter contains the maintenance procedures for the CAU (screw cap application unit). The chapter is only valid if the machine is equipped with a CAU, the chapter is ignored for all other machines. The Functional Description on page Functional Description provides a technical description of the screw cap application unit.Hygiene Risk
Hygiene risk.Do not touch the screw caps.The screw caps can become contaminated.
Make sure that you do not contaminate the caps, the CAU or the CSU at any time. Always wash and disinfect your hands and gloves before touching parts that must be hygienic.Package Changes
The lid of the package has no Membrane. The Screw cap is the sealing on the top of the package.The Screw cap is equipped with a Tamper ring, for tamper evidence.
- Membrane
- Tamper ring
- Screw cap
Duct and Sprue Box
When the lid is manufactured with inlet moulding, there is a leftover called Sprue. The Sprue is separated from the lid with the Knife.The Sprue falls through the Duct, down to the Sprue box. The Sprue box can be reached by opening the Hatch.The Hatch can be opened during PRODUCTION in order to empty the Sprue box. The Sprue box needs to be emptied every third production hour.When 11 000 packages have been produced according to the count on the TPOP, a blue alarm occurs. Empty the Sprue box and reset the blue alarm. If this is not done a yellow alarm will occur on the TPOP when the photocell for the Sprue box is activated. When the blue alarm has been active for 3 seconds the machine will step down to tankfilling on the affected machine side.
- Duct
- Knife
- Sprue
- Sprue box
- Hatch
Transfer Unit
The packages are transferred into the Magazine, by the LFU -stripper. The packages will then be rotated one revolution in the Magazine. This is done to cool down the lid before fitting the screw cap.After one revolution the CAU stripper will move the packages into the Capping station. The CAU stripper is driven by the Drive unit.If there are packages in the capping station in this moment, they will be moved to the Cassette in the package section by the CAU stripper in the same stroke.Note: It is possible to open the upper forming pipes in the Capping station, to remove packages. See further instruction in the Operator Manual.
- Magazine
- Drive unit
- CAU stripper
- Cassette
- Capping station
Screw Cap Applicator Unit
The screw cap is assembled when the package is positioned in the Capping station. It is the Screw Cap applicator unit that applies the screw cap to the package.While the CAU stripper moves packages and places new packages in the Capping station, the Screw Cap applicator unit moves down and away (forward) from the Capping station to pick up new screw caps from the screw cap handling unit (the screw cap handling unit will be described later).Then the Screw Cap applicator unit moves up and toward (backward) the capping station, to position the screw caps in front of the packages in the Capping station. Finally the Screw Cap applicator unit starts to rotate the screw caps and the CAU stripper moves the packages toward the screw cap to assemble them. When the screw caps have been assembled, the cycle start over again.
- CAU stripper
- Capping station
- Screw Cap applicator unit
Screw Cap Handling
The screw caps are blown up from the CSU to the Cyclone. From the Cyclone, the screw caps fall down into the Screw cap sorter. The Screw cap sorter turns all screw caps with the same side down to align them, then the Screw cap sorter distributes the screw caps down the Chute.The screw caps are transported down the Chute. Further down the chute they are divided between two chutes to supply both sides of the Screw cap transfer.
- Cyclone
- Screw cap sorter
- Chute
- Screw cap transfer
The Loading piston transfers the screw cap through the Tube into the Screw Cap Holder in the screw cap applicator unit. The Screw Cap Holder rotates the Screw cap to match the heels in the screw cap with the heels on the loading piston and registers the screw cap position. The loading piston moves back and the screw cap applicator unit lifts the screw cap and assembles it to the package as described earlier.
- Tube
- Screw Cap Holder
- Loading piston
- Screw cap
CSU
The CSU feeds one TT/3 with screw caps. There are two sides in the CSU, S1 and S2 (see illustration). Each side contains a Container, and a Fan. One side of the CSU serves one production side on the CAU with screw caps.The Electrical cabinet serves both sides of the CSU.One Container has the capacity to hold 15 000 screw caps. A full Container can be emptied in two minutes, using the emptying function.
- CSU
- Container
- Fan
- Electrical cabinet
The screw caps are stored in the Container. From the Container they fall down on the Conveyer. The Vibrator shakes the container to keep the screw caps from becoming jammed at the bottom of the Container.The Conveyer transports the screw caps until they fall down into the HEPA -filtered air stream that is driven by the Fan. Then the screw caps are blown through the Outlet, and through the pipe that leads to the screw cap sorter on top of the screw cap applicator unit in the TT/3.
- Container
- Conveyer
- Vibrator
- Fan
- Outlet
To perform certain maintenance procedures or to change screw cap colour, it is necessary to empty the CSU from screw caps. An emptying function is built in for this purpose. The Hatch must be folded out according to the illustration. When the Push button is pushed, the Conveyer will reverse. Then the screw caps will be transported out through the Hatch. For further instructions about the emptying procedure, see the Operation Manual (OM).When the level of screw caps is low in the CSU, a blue alarm occurs. When the CAU is emptied, the blue alarm will remain.
- Conveyer
- Hatch
- Push button
Vision Unit
The vision unit ejects packages when the screw cap is not properly attached. It is a pneumatic cylinder that ejects packages. There is also a cylinder for volume change with two different positions depending on package height. The camera takes care of the fine adjustment automatically. For example, BASE 750 and BASE 1000 uses the same position of the volume change cylinder which the camera can handle, while for example BASE 500 and BASE 1000 use different positions for the volume change cylinder.Setting Sequence CAU
Also check all settings for photocells and sensors.Alarms and Troubleshooting CAU
Overview
| Pos. | Cross reference |
| 1 | See 110307771/110307772, Magazine S1/S2, Sleeve Stuck |
| 2 | See 110307811/110307812, Magazine S1/S2, Servo Fault |
| 3 | See 110307791/110307792, Capping Station S1/S2, Sleeve Stuck |
| 4 | See 110307821/110307822, CAU Stripper, Servo Fault |
| 5 | See 110307781/110307782, CSU S1/S2, Low Level |
| 6 | See 110307741/110707631/110307742/110707632, CSU S1/S1/S2/S2, Lid or Door Open |
| 7 | See 110307751/110307752, CSU S1/S2, Fan Malfunction |
| 8 | See 110307710, Overload protection tripped CSU |
| 9 | See 110630050, CAU Emergency Stop |
| 10 | See 110307761/110307762, CSU, Belt Malfunction S1/S2 |
| 11 | See 110307831/110307841/110307832/110307842, Capper Unit S1:1/S1:2/S2:1/S2:2, Servo Fault |
| 12 | See 110307721/110307722, Capper Unit S1/S2, Horizontal Cylinder Wrong Pos |
| 13 | See 110307610, Output Module, Fuse Blown |
| 14 | See 110307600, CAU Section, DeviceNet Error |

| Pos. | Cross reference |
| 15 | See 110307861/110307862 Sprue Stuck in Chute |
| 16 | See 110307681/110307682, Sprue Box S1/S2, High Level |
| 17 | See 110307851/110307852, Capper Unit S1/S2, Screw Cap Not Correctly Loaded |
| 18 | See 110307731/110307732, Capper Unit S1/S2, Screw Capping Failed |
| See 110307911 / 110307912 / 110307921 / 110307922, S1:1 / S1:2 / S2:1 / S2:2, Cap Orientation Failed |
| See 110307931 / 110307932 / 110307941 / 110307942, S1:1 / S1:2 / S2:1 / S2:2, Unsafe Start Angle for Controlled Capping |
| 19 | See 110307801/110307802, Screw Cap Lift S1/S2, Servo Fault |
| 20 | See 110307661/110307662, Screw Cap Chute S1/S2, Low Level |
| 21 | See 110307641/110307642, Screw Cap Sorter S1/S2, Warm Motor Overload |
| 22 | See 110707711/110707712, Screw Cap Sorter S1/S2, Low Level |
| 23 | See 110307691/110307692, Screw Cap integrity fault from Vision system S1/S2 |
| 24 | See 110307701/110307702, Function Warning Vision system S1/S2 |
| 25 | See 110307671/110307672 Communication Error Vision System |
| 26 | See 110307871/110307872 Missing Package from Cap Vision System |
| 27 | See 110307011/110307012 SleeveStop S1/S2, Wrong position |
110307771/110307772, Magazine S1/S2, Sleeve Stuck
DescriptionThe Photocell controls if there are any Sleeve in the Magazine. The Photocell reads across the upper pair of Sleeve forming device, towards the Reflector, see illustration.Conditions to set the alarmThe alarm will be set if there are sleeves present when there are not supposed to be any sleeves and vice versa. This is detected by the Photocell (G31B1227 for side1 and G31B2227 for side2).
- Photocell
- Sleeve
- Magazine
- Sleeve forming device
- Reflector
Troubleshooting110307811/110307812, Magazine S1/S2, Servo Fault
DescriptionThe Motor rotates the Magazine. If this alarm is set, it indicates that something is wrong with the position or movement of the Magazine.
- Motor
- Magazine
Conditions to set the alarmThis alarm is a summary alarm and can be caused by a numerous of reasons, mechanically and electronically. The electronically reasons are the same for every servo axis in the machine. The alarms that are likely to be mechanically connected are the following.Position error faultMotor overtemp fault
Position error fault is set due to that something suddenly is disturbing the motion of the mechanics. This could be some kind of obstacle (a loose bolt etc), lack of lubrication, a stuck ball bearing.Motor overtemp fault is similar to the above fault but here the disturbance is not that sudden. If the motor for some reason is forced to work harder it will become hot and the Motor overtemp fault will occur. The cause could be slowly degrading lubrication, wear of bearings and guides, or basically that the environment (i.e. cooling capacity) around the motor has changed.Troubleshooting- Look for any obvious obstacles in the magazines movement. Try to rotate the mechanics manually to check that it moves smoothly.
- Check that the motor, the gearbox and the rest of the mechanics are properly fixed (loose bolts etc).
- Check that the electrical connections are properly connected, both to the motor and to the servo drive in the electrical cabinet. Also inspect the cables to make sure that they are not damaged.
- If the magazines home position is out of place, set according to:Magazine - Set Home Position.
110307791/110307792, Capping Station S1/S2, Sleeve Stuck
DescriptionThe Fibre optics checks if there are any Sleeve in the Capping station. The Fibre optics reads across the Capping station.Conditions to set the alarmThe alarm will be set if there are sleeves present when there are not supposed to be any sleeves and vice versa. This is detected by the Fibre optics (G31B1228 for side 1 and G31B2228 for side 2).
- Fibre optics
- Sleeve
- Capping station
Troubleshooting110307821/110307822, CAU Stripper, Servo Fault
DescriptionThe Motor runs the Linear unit. If the alarm is set, it indicates that something is wrong with the movement of the CAU stripper.
- Motor
- Linear unit
- CAU stripper
Conditions to set the alarmThis alarm is a summary alarm and can be caused by a numerous of reasons, mechanically and electronically. The electronically reasons are the same for every servo axis in the machine. The alarms that are likely to be mechanically connected are the following.Position error faultMotor overtemp fault
Position error fault is set due to that something suddenly is disturbing the motion of the mechanics. This could be some kind of obstacle (a loose bolt etc), lack of lubrication, a stuck ball bearing.Motor overtemp fault is similar to the above fault but here the disturbance is not that sudden. If the motor for some reason is forced to work harder it will become hot and the Motor overtemp fault will occur. The cause could be wear of bearings and guides, or basically that the environment (i.e. cooling capacity) around the motor has changed.Troubleshooting- Look for any obvious obstacles in the CAU stripper. Try to move the mechanics manually to check that it moves smoothly.
- Check that the motor, the gearbox and the rest of the mechanics are properly fixed (loose bolts etc).
- Set the parallelism of the CAU stripper according to:CAU Stripper - Set.
- Check the setting of the drive unit according to:Drive Unit - Set Linear Unit.
- Set the home position for the linear unit according to:Drive Unit - Set Home Position.
- Check that the electrical connections are properly connected, both to the motor and to the servo drive in the electrical cabinet. Also inspect the cables to make sure that they are not damaged.
110307781/110307782, CSU S1/S2, Low Level
DescriptionThe Photocell detects that there are screw caps in the Container.Conditions to set the alarmIf no screw caps are detected during 10seconds a blue alarm will occur on the TPOP.Troubleshooting
- Photocell
- Container
110307741/110707631/110307742/110707632, CSU S1/S1/S2/S2, Lid or Door Open
Description110307741 = Yellow alarm S1110707631 = Blue alarm S1110307742 = Yellow alarm S2110707632 = Blue alarm S2
Conditions to set the alarmWhen a lid or a door is open a blue alarm will occur on the TPOP. If the lid or door remains open for more then 10 minutes a yellow alarm will occur and the machine will step down to HEATING.Troubleshooting110307751/110307752, CSU S1/S2, Fan Malfunction
DescriptionThe Motor runs the Fan.Conditions to set the alarmThe alarm, which is a summary alarm, indicates that there is something wrong with the motor or the frequency converter.
- Motor
- Fan
Troubleshooting- Make sure that the fan can rotate freely.
- Reset the overload protection for the motor.
- Check electrical terminals for bad connections.
110307710, Overload protection tripped CSU
DescriptionIn the CSU electrical cabinet there is a overload protection.Conditions to set the alarmIf this alarm occurs on the TPOP it indicates that something is wrong with the overload protection in the CSU electrical cabinet.Troubleshooting- Reset the overload protection for the motor.
- Make sure that there is power to the connections for the overload protection.
- Check electrical terminals for bad connections.
110630050, CAU Emergency Stop
DescriptionThe CSU unit is equipped with an Emergency stop push-button that can be used to short stop the unit in case of emergency.Conditions to set the alarmIf the Emergency stop push-button is pushed, the alarm will occur on the TPOP.Troubleshooting- Deactivate the Emergency stop push-button and step up the machine again.
- Check the safety circuit for bad connections.
- Change the safety relay.

- CSU
- Emergency stop push-button
110307761/110307762, CSU, Belt Malfunction S1/S2
DescriptionThe Motor runs the Fan. Conditions to set the alarmThe alarm, which is a summary alarm, indicates that there is something wrong with the motor or the frequency converter.
- Motor
- Fan
Troubleshooting- Make sure that the belt can rotate freely.
- Reset the overload protection for the motor.
- Check electrical terminals for bad connections.
110307831/110307841/110307832/110307842, Capper Unit S1:1/S1:2/S2:1/S2:2, Servo Fault
DescriptionThe Servomotor runs the Screw cap holder. An alarm on the TPOP regarding the Servomotor, indicates that something is wrong with the Servomotor.
- Servomotor
- Screw cap holder
Conditions to set the alarmThis alarm is a summary alarm and can be caused by a numerous of reasons, mechanically and electronically. The electronically reasons are the same for every servo axis in the machine.If the motor for some reason is forced to work harder it will become hot and the motor overtemp fault will occur. The cause could be changes in tension of a transmission belt, slowly degrading lubrication, wear of bearings and guides, or basically that the environment (i.e. cooling capacity) around the motor has changed.Troubleshooting- Try to rotate the mechanics manually to check that it moves smoothly. Check that the motor and the rest of the mechanics are properly fixed (loose bolts etc).
- Check that the electrical connections are properly connected, both to the motor and to the servodrive in the electrical cabinet. Also inspect the cables to make sure that they are not damaged.
- If the servomotor is broken, change according to:Capper Unit - Change Servomotor.
- Check the tension of the timing belt according to:Capper Unit - Set Timing Belt.
110307721/110307722, Capper Unit S1/S2, Horizontal Cylinder Wrong Pos
DescriptionBefore the screw cap is fitted in the Screw cap holder, the Capper unit must be moved against the Tube.When the screw cap has been attached to the package, the Capper unit must be moved away from the package, before it is lowered.The movement of the Capper unit, in horizontal direction, is performed by the Cylinder, and it is monitored by the Proximity sensor and Proximity sensor.
- Tube
- Screw cap holder
- Capper unit
- Proximity sensor
- Proximity sensor
- Cylinder
Conditions to set the alarmIf it takes more then 350ms for the cylinder to reach fully retracted position, or more than 200ms to reach fully extended position, the alarm will occur on the TPOP. This is detected by sensor G31B1221 and G31B1222 (side 1) and G31B2221 and G31B2222 (side 2) respectively.Troubleshooting- Make sure there are no obstacles of any kind in the way of the capping cylinders movement. Manually move the capping cylinder back and forward to check that it moves smoothly.
- If there is a play in the capping cylinder, it might indicate that the cylinder needs to be changed according to:Capper Unit - Change Cylinder
- Set the movement of the capping cylinder by setting the pneumatic valves according to:Screw Cap Lift - Set Pneumatic Valve
- Make sure that the capper unit is correctly lined up according to:Capper Unit - Basic Set
- Set the sensors on the capping cylinder, according to:Capper Unit - Set Sensor
- If one or more of the sensors on the capping cylinder is broken, change according to:Capper Unit - Change Sensor
110307610, Output Module, Fuse Blown
DescriptionThis is a summary alarm for all electronic fuses in the CAU DeviceNet nodes.Conditions to set the alarmIf a DeviceNet output module on the CAU is overloaded, this alarm will be set.Troubleshooting- Check that the electrical connections are properly connected.
- Switch OFF and ON the DeviceNet node.
- Change DeviceNet module.
- Tighten all unused connections.
110307600, CAU Section, DeviceNet Error
DescriptionThis is a alarm that indicates a failure in the CAU DeviceNet.Conditions to set the alarmIf the DeviceNet communication fails or if two nodes has the same address or if the DeviceNet nodes are in incorrect order, this alarm will be set.Troubleshooting110307861/110307862 Sprue Stuck in Chute
DescriptionIf sprues for some reason are getting stuck in the chute (that is, the bottom part of the chute is incorrectly mounted), the photocell (G31B1307/G31B2307) will detect if the chute is blocked.Conditions to set the alarmIf the photocell is activated, a yellow alarm will occur on the TPOP and the machine will be brought to a direct stop. This to avoid sprues from falling out of the chute.Troubleshooting110307681/110307682, Sprue Box S1/S2, High Level
DescriptionThe excess plastic from the moulding of the package lid is called sprue. The sprue is cut off from the lid and collected in the Sprue box. The Photocell (G31B1223 side 1 or G31B2223 side 2) detects if the Sprue box is full.Conditions to set the alarmWhen 11000 packages (default value, can differ according to TPOP setting) has been produced according to the count on the TPOP, a blue alarm will occur and an attention signal will sound. Empty the Sprue box and reset the blue alarm on the TPOP. Zero the count by pressing Zero on the TPOP. If this is not done a yellow alarm will occur on the TPOP when the Photocell for the Sprue box is activated. When the yellow alarm has been active for 3 seconds the machine will step down to tankfilling on the affected machine side.
- Sprue box
- Photocell
- Zero
110307851/110307852, Capper Unit S1/S2, Screw Cap Not Correctly Loaded
DescriptionThe screw cap Transfer cylinder pushes new screw caps in to the Screw cap holder for each capping cycle.Conditions to set the alarmIf the Transfer cylinder has not reached fully extended position within a certain time, the alarm will occur on the TPOP. This is detected by Sensor (G31B1226 on side 1 or G31B2226 on side 2).
- Sensor
- Transfer cylinder
- Loading piston
- Screw cap holder
Troubleshooting- A probable cause of this alarm is that two screw caps has been delivered to the capping position at the same time (double screw cap).
- Make sure there are no obstacles of any kind in the way of the screw cap transfer unit. Manually move the transfer cylinder back and forward to check that it moves smoothly.
110307731/110307732, Capper Unit S1/S2, Screw Capping Failed
DescriptionThe control system (PLC) monitors and evaluates different parameters (torque and rotational angel) during the capping process in order to determine that the screw cap has been successfully applied.Conditions to set the alarmIf the machine fails to fulfil the above demands for four machine cycles in a row, a yellow alarm will occur on the TPOP and the machine will step down the affected machine side.Troubleshooting110307801/110307802, Screw Cap Lift S1/S2, Servo Fault
DescriptionThe Motor runs the Compact module, that the Capper unit is attached to. The alarm indicates that something is wrong regarding the vertical movement.
- Motor
- Compact module
- Capper unit
Conditions to set the alarmPosition error faultMotor overtemp fault
Position error fault is set due to that something suddenly is disturbing the motion of the mechanics. This could be some kind of obstacle (a loose bolt etc), lack of lubrication, a stuck ball bearing.Motor overtemp fault is similar to the above fault but here the disturbance is not that sudden. If the motor for some reason is forced to work harder it will become hot and the Motor overtemp fault will occur. The cause could be changes in tension of a transmission belt, slowly degrading lubrication, wear of bearings and guides, or basically that the environment (i.e. cooling capacity) around the motor has changed.Troubleshooting- Look for any obvious obstacles in the capper units movement.
- Try to move the mechanics up and down manually to check if the compact module has a bad function.
- Check that the motor, the gearbox and the rest of the mechanics are properly fixed (loose bolts etc).
- Check that the electrical connections are properly connected, both to the motor and to the servo drive in the electrical cabinet. Also inspect the cables to make sure that they are not damaged.
- Check that the guides are well lubricated. If necessary lubricate according to:Screw Cap Lift - Lubricate Compact Module
- Check the position of the loading pistons in the transfer unit and make sure they are moving without interfering with the screw cap holders.
- Set the sensors according to:Screw Cap Transfer - Set Sensor
110307661/110307662, Screw Cap Chute S1/S2, Low Level
DescriptionThe Photocell on the Chute controls the Screw cap sorter.Conditions to set the alarmIf no screw caps are delivered from the Screw cap sorter within a specific time a yellow alarm will occur on the TPOP.If the cause of the alarm disappear or are removed within 90 seconds, the machine will be automatically restarted. If not, the machine will step down to machine step Tank Filling
- Photocell
- Chute
- Screw cap sorter
Troubleshooting110307641/110307642, Screw Cap Sorter S1/S2, Warm Motor Overload
DescriptionThe Motor runs the Screw cap sorter. Conditions to set the alarmThe alarm, which is a summary alarm, indicates that there is something wrong with the motor or the frequency converter.The specific fault is displayed in the window of the frequency converter (G31T1022, side 1 or G31T2022, side 2) as an error number.
- Motor
- Screw cap sorter
Troubleshooting- Make sure the mechanism inside the screw cap sorter can rotate freely.
- Reset the overload protection for the motor.
- Check the fuse number 82 in the main electrical cabinet.
- Check electrical terminals for bad connections.
110707711/110707712, Screw Cap Sorter S1/S2, Low Level
DescriptionThe Photocell controls the level in the Screw cap sorter.Conditions to set the alarmIf the Photocell detects a low level of screw caps for 25 seconds, a yellow alarm will occur on the TPOP. The machine will then step down the affected machine side.
- Screw cap sorter
- Photocell
- Reflector
Troubleshooting110307691/110307692, Screw Cap integrity fault from Vision system S1/S2
DescriptionWhen a package passes the camera on the conveyer, the height difference between the Screw cap and the Package edge is measured. If this distance is outside a certain interval, the package will be wasted. The interval is the average height of the last 200 produced packages plus TPOP setting.When a package passes the camera on the conveyer, the angular difference between the Screw cap and the Package edge is measured. If this angle is above the value set on TPOP, the package will be wasted.Conditions to set the alarmIf three out of the latest 30 packages are rejected, a yellow alarm will occur on the TPOP and the machine will be stepped down to tank filling.
- Screw cap
- Package edge
Troubleshooting- If the yellow light on the camera lights, restart it by cycling power:Vision Unit - Cycle Power
- Perform the fine adjustment for the vision unit according to:Vision Unit- Set fine adjustment with PC
- Make sure that the conveyer speed is correct. It must be 15m/min.
- If the location where the camera measures is exposed to direct sunlight, the function of the camera might be disturbed. Take measures to cover the sunlight.
- Check the photocell. Set or change, if necessary:Photocell - CheckPhotocell - SetPhotocell - Change
- Clean the camera lens according to:Chapter 8 Care and Cleaning in the Operation Manual.
- Perform the mechanical settings for the camera unit according to:Vision Unit - Set Position
- Check that the camera is properly fixed.
- Check that the camera volume change cylinder is properly fixed.
110307701/110307702, Function Warning Vision system S1/S2
DescriptionBad reading results.Yellow function light indicates reading in progress.Red function light indicates tilted screw cap or internal program fault, for example communication fault. Red function light can also indicate that the photocell is activated but there is no package in reading position.Green function light indicates everything OK.Conditions to set the alarmIf the camera do not recognise the reading as a package a blue alarm will occur on the TPOP.Troubleshooting- If the red light on the camera lights, restart it by cycling power:Vision Unit - Cycle Power
- Read through the information under:Functional Description in Vision Unit
- Check the air pressure.
- Make sure that the power supply for the camera is active.
- Check the photocell, set or change if necessary:Photocell - CheckPhotocell - SetPhotocell - Change
- If the location where the camera measures is exposed to direct sunlight the function of the camera might be disturbed. Take measures to cover the sunlight.
- Clean the camera lens according to:
- Perform the mechanical settings for the camera unit according to:Vision Unit - Set Position
- Make sure that the conveyer speed is correct, it must be 15m/min.
110307671/110307672 Communication Error Vision System
DescriptionCommunication fault.Yellow function light indicates reading in progress.Red function light indicates tilted screw cap or internal program fault, for example communication fault. Red function light can also indicate that the photocell is activated but there is no package in reading position.Green function light indicates everything OK.Green blinking function light indicates that the camera is waiting for a signal from the PLC. The signal is sent when the machine is in step production.Conditions to set the alarmIf the communication between the camera and the TT/3 machine fails.Troubleshooting110307871/110307872 Missing Package from Cap Vision System
DescriptionThis alarm prevents the machine from running if no packages are detected by the vision system.Conditions to set the alarmIf the machine is running but no packages are detected by the vision system for five minutes.Troubleshooting110307911 / 110307912 / 110307921 / 110307922, S1:1 / S1:2 / S2:1 / S2:2, Cap Orientation Failed
DescriptionWhen the loading piston inserts the screw cap into the screw cap holder, the control system (PLC) orients the screw cap by rotating it. The heels in the screw cap then grip together with the notches on the loading piston. The PLC monitors how many degrees the screw cap is rotated and how long it takes to find the heels in the screw cap.Conditions to set the alarmIf the machine fails to orient three screw caps within 30 seconds, a yellow alarm will occur on the TPOP and the machine will step down the affected machine side.Troubleshooting- Check that a cap is present in the cap holder to be applied to the neck. Missing cap can not be detected by the machine so the alarm will be Cap Orientation failed. see Troubleshoot - Cap Torque Error and Tilted Caps.
- Check that the screw caps have heels.
- Check the function of the loading pistons.
- Set the cap transfer position for the screw cap lift. See Procedure Screw Cap Lift - Set End Positions.
- Check the function of the screw cap holder servomotors.
110307931 / 110307932 / 110307941 / 110307942, S1:1 / S1:2 / S2:1 / S2:2, Unsafe Start Angle for Controlled Capping
DescriptionThe control system (PLC) monitors how many degrees the screw caps are rotated when assembled on to the neck of the packages. The standard deviation of degrees that the screw caps are rotated is small if the machine is running correctly. The illustrations below show examples of when Controlled Capping is running correctly and when it is running poorly.
Running correctly.

Running poorly.
Conditions to set the alarmIf the PLC senses that the machine has been running in an unsafe area for more than 60 seconds, a yellow alarm will occur on the TPOP and the machine will step down on the affected machine side.Troubleshooting110307011/110307012 SleeveStop S1/S2, Wrong position
DescriptionThe Proximity Switch controls if Sleeve Stop movement is in correct position during the Magazine plate movement. 
- Proximity Switch
- Sleeve Stop
- Magazine plate
Condition for alarm The proximity switch G31B1338/G31B2338 detects if the Sleeve Stop is in wrong position between sector value range 1500-0200 and 0550-1200, during step MOTOR RUNNING, PRODUCTION or PRODUCTION END when CAU Magazine is in movement.If the Sleeve Stop is not in lower position during step HEATING.When the alarm is triggered:- The production stops on the affected machine sides.
- The affected machine side stops cutting new blanks, but fills and finishes all the packages that are currently in the package section.
- The unaffected machine side continues to run.
TroubleshootingTroubleshoot - Cap Torque Error and Tilted Caps
2000 | Equipment Status | Program Step production |
Introduction
In the case of sporadic machine issues spread out over time, package waste figures for cap torque and tilted cap can be high even though the machine is not stopped for a specific alarm.The reason being that the software is configured to only stop the machine if the same failure mode happens several times in a row or during a short period of time.This trouble shooting guide is for that reason using the waste as origin instead of an alarm from TPOP.Troubleshoot - Quick Guide
Troubleshoot - Cap Torque Error Waste
Cap Torque Error, High WasteTo guarantee that the cap is properly attached to the neck, the capping sequence has a quality control.The cap is applied with a set torque and how many degrees the cap turns is measured.If the cap turns more than allowed it indicates an incorrect capping, the package will then not be filled and wasted in front of the machine.The torque error can come from that a cap is not in place to be capped, so analysing the waste is the first step in finding the root cause of the problem.Flow charts Torque Error Waste| Torque Error Waste |
| | | | | | | | | | | | | |
| | | | | | | | | | | | | | |
| | | | | | | | | | | | | | |
| Wasted packages with caps | | Wasted packages without caps |
| | | | | | | | | | | | |
| | | | | | | | | | | | | | |
| Wasted packages with Caps |
| | | | | | | |
| Cap slips over the thread of the package neck | | Cap slips in the cap holder | | Orientation or capping toque sequence has not been fulfilled (No alarm due to random occurrence) |
| | | | | | | |
| Lower torque setting according to OM | | 4.6.1-16 Capper Unit - Check Cap Holder4.6.1-15 Capper Unit - Change Cap Holder | | Check the mechanical settings related to the synchronization of the sleeve transfer and the cap application.4.4.4-1 CAU Stripper - Set4.4.4-2 CAU Stripper - Set Capping Reference4.4.3-7 Drive Unit - Set Stop Plate4.4.3-2 Drive Unit - Set Home Position |
| Wasted packages without Caps |
| | | | | | | | | | | | | | | | | | | |
| Wasted caps on top of the CAU sprue box |
| | | | | | | | | | | | | | | | | | | |
| Wrongly turned caps in the cap holder | | Sleeve bottom collapses during the transfer through CAU | | Package top collapses when the cap is applied (turtle neck) | | Caps get stuck or fall over in the cap transfer |
| | | | | | | | | | | | | | | | | | | |
| 4.5.2-3 Screw Cap Sorter - Set Valve | | 2.4.3-1 Sleeve Forming Unit - Check Size for Sleeve | | Check the lid blowing in the LFU3.3.2-3 Swivel/Connection - Check Lid Blower | | Check the neck temperature | | Check the masterbatch and the PE mixing3.9.4-1 Metering Device - Set | | Check the lid thickness according to the OM Package Checks | | Check that the pusher is pulled back far enough to allow the caps to enter the bushing (loading position).4.5.1-11 Screw Cap Transfer - Set Rear Position of the Cylinder |
| | | | | | | | | | | | | | | | | | | |
| | | | | | Check cooling water temperature and flow to LFU molding tools3.14.1-2 Cooling Water System - Check Flow | | | | | | If the caps fall over in the cap transfer, it is usually due to lost queue pressure. The leaf spring should only be needed to hold the first cap upright during the fill up of the system.Add discharge chute and chute assembly here when created. |
| | | | | | | | | | | | | | | | | | | |
| | | | | | | | | Check hot channel temperature and ensure correct position of thermocouple3.8.1-11 Hot Channel - Check Temperature and Heating Cartridges | | | | | | | | | |
| Wasted packages without CapsValid for: MKC CAU Cap Chute Cylinder TT3 3699767-0100 |
| | | | | | | | | | | | | | | | |
| No wasted caps on top of the CAU sprue box |
| | | | | | | | | | | | | | | | |
| No caps in the cap sorter | | Caps are getting stuck in the sorter | | Cap sorter feeding capacity is low | | Caps get stuck in the Y-divider of the chute | | Caps get stuck in the lid joints of the chute | | Caps get stuck in the middle of the chute |
| | | | | | | | | | | | | | | | |
| Check the CSU level. Refill if needed. | | 4.5.2-3 Screw Cap Sorter - Set Valve | | Check that the correct cap is chosen on the TPOP. The sorter speed is optimized towards the cap type. | | Check that the Direction Guide is set correctly.4.5.3-4 Chute - Set Direction Guide and Plate, valid for O384.5.3-10 Chute - Check Cap Chute Cylinder | | Check that the lid is firmly installed on the chute. Adjust fasteners if needed. | | Check that the plastic window is fully glued to the lid. |
| | | | | | | | | | | | | | | | |
| Set the fan speed if the caps get stuck in the transfer pipe.4.9.2-1 Feed Unit - Set Fan Speed | | | | | | Check that the Discharge Chutes are completely closed by adjusting the cylinder.4.5.4-1 Discharge Chute - Change Pneumatic Cylinder | | Check the chamfers on the plastic window of the lid so there are no edges in the cap flow direction. | | Check that the correct lid is used (O38 has 2mm, C38 has 3mm plastic window). |
| | | | | | | | | | | | | | | | |
| | | | | | | | | Check that the chute is correctly assembled towards the cap transfer holder. | | | | | Check that the lids are not bent. |
| | | | | | | | | | | | | | | | |
| | | | | | | | | | | | | | | Check that no loose particles (ex. tamper evidence ring) are present in the chute. |
| Wasted packages without CapsNot valid for: MKC CAU Cap Chute Cylinder TT3 3699767-0100 |
| | | | | | | | | | | | | | | | |
| No wasted caps on top of the CAU sprue box |
| | | | | | | | | | | | | | | | |
| No caps in the cap sorter | | Caps are getting stuck in the sorter | | Cap sorter feeding capacity is low | | Caps get stuck in the Y-divider of the chute | | Caps get stuck in the lid joints of the chute | | Caps get stuck in the middle of the chute |
| | | | | | | | | | | | | | | | |
| Check the CSU level. Refill if needed. | | 4.5.2-3 Screw Cap Sorter - Set Valve | | Check that the correct cap is chosen on the TPOP. The sorter speed is optimized towards the cap type. | | Check that the Direction Guide is set correctly.4.5.3-3 Chute - Set Valve, valid for C384.5.3-7 Chute - Set Direction Guide and Plate, valid for C384.5.3-4 Chute - Set Direction Guide and Plate, valid for O38 | | Check that the lid is firmly installed on the chute. Adjust fasteners if needed. | | Check that the plastic window is fully glued to the lid. |
| | | | | | | | | | | | | | | | |
| Set the fan speed if the caps get stuck in the transfer pipe.4.9.2-1 Feed Unit - Set Fan Speed | | | | | | Check that the Discharge Chutes are completely closed by adjusting the cylinder.4.5.4-1 Discharge Chute - Change Pneumatic Cylinder | | Check the chamfers on the plastic window of the lid so there are no edges in the cap flow direction. | | Check that the correct lid is used (O38 has 2mm, C38 has 3mm plastic window). |
| | | | | | | | | | | | | | | | |
| | | | | | | | | Check that the chute is correctly assembled towards the cap transfer holder. | | | | | Check that the lids are not bent. |
| | | | | | | | | | | | | | | | |
| | | | | | | | | | | | | | | Check that no loose particles (ex. tamper evidence ring) are present in the chute. |
Troubleshoot - Tilted Cap Waste
In case of high waste, perform a screening. See Controlled Capping - Set Start-Angle. If the problem still occurs, analyse the waste using the following chart.Flow charts Tilted Cap Waste| Tilted Cap Waste |
| | | | | | | | | | | | | | | | | | | |
| | | | | | | | | | | | | | | | | | | | |
| | | | | | | | | | | | | | | | | | | | |
| Wasted packages have tilted caps | | Wasted packages do not have tilted caps |
| | | | | | | | | | | | | | | | | | |
| | | | | | | | | | | | | | | | | | | | |
| | | | | | | | | | | | | | | | | | | |
| Wasted packages have tilted caps |
| | | | | | | | | | | | | | | | | | | |
| Waste is from the same inner moulding tool | | Waste is from the same part line | | Waste is random |
| | | | | | | | | | | | | | | | | | | |
| Check the moulding tool for ware | | Check the neck temperature | | Check the mechanical settings related to the synchronization and concentricity of the sleeve transfer and the cap application. | | Check the incoming cooling water temperature to the machine |
| | | | | | | | | | | | | | | | | | | |
| Check the cooling water flow through the tool | | Check the cooling water temperature and the flow to the LFU moulding tools | | Check the hot channel temperature and ensure the correct position of the thermocouple | | Cap loading | | Capping position | | Stripper settings | | | |
| | | | | | | | | | | | | | | | | | | |
| | | 3.14.1-2 Cooling Water System - Check Flow | | 3.8.1-11 Hot Channel - Check Temperature and Heating Cartridges | | 4.6.2-3 Screw cap lift - Set End Positions | | 4.6.2-3 Screw cap lift - Set End Positions | | 4.4.4-1 CAU Stripper - Set | | | |
| | | | | | | | | | | | | | | | | | | |
| | | | | | | | | 4.5.1-11 Screw Cap Transfer - Set Rear Position of the Cylinder | | 4.5.1-2 Screw Cap Transfer - Set Parallelism | | 4.4.3-7 Drive Unit - Set Stop Plate | | | |
| | | | | | | | | | | | | | | | | | | |
| | | | | | | | | | | | 4.5.1-3 Screw Cap Transfer - Set Overloading | | 4.4.4-2 CAU Stripper - Set Capping Reference | | | |
| | | | | | | | | | |
| Wasted packages do not have tilted caps |
| | | | | | | | | | |
| Check the Vision Unit | | Protect the reading area from sunlight | | Check the conveyor for speed and vibration according to the IM | | Check that packages are not queued |
| | | | | | | | | | |
| 4.10-8 Vision Unit - Check incorrect read via TPOP | | | | | | | | | |
CSU Air Speed - Check
According to the Maintenance Manual, the airspeed must not exceed 10 m/s. However, the best solution is for the airspeed to be as slow as possible. See Procedure Feed Unit - Set Fan Speed .- If you do not have an airspeed measuring device, slow down the fan 1 Hz at a time. Run the machine for 10 to 15 minutes.
- Repeat this step until the CSU fails to supply the machine with caps. Then empty the system of caps, increase the speed by 2 Hz, and then restart production. This is the best CSU airspeed for this equipment.
Cap Trap Lid, Guide, Air, Nozzle - Check
| Equipment Status | Air must be turn OFF. Program Step |
Ensure Parts Installed
- Check and make sure that the following parts are installed correctly:

- Air return pipe
- Air nozzle
- Cap return air regulator
- Cap trap air regulator
- Direction guide
- Screw
Secure the Correct Position of the Blow Nozzle
- Disassemble the cap trap.
- Mark the centre of the trap on the lid with a marker when the lid is in the position as shown in the image.
- Turn the cap trap lid over and mark it on the other side too.
- Hold the pipe in the correct position. Put the blow nozzle behind the centre, otherwise the caps get stuck in the cap trap.
Cap Chute Lids - Check
| Equipment Status | Air must be turn OFF. Program Step |
- Check that the cap chute lids are tight. No gap is allowed.

A = 0 mm
- Check that the plexiglass is 3 mm thick.Note: If the thickness is 2 mm, it is the wrong type of plexiglass.

B = 3 mm
- Check that the transitions are smooth as shown in the image.
If the cap chute lids incorrectly mounted or are the wrong type, there is a risk that the caps get stuck as shown in the illustrations. Incorrectly mounted chute lids or the wrong type of lid causes problems with cap loading, cap orientation, and so on.
Climbing caps
Direction Guide, Air Nozzle - Check
| Equipment Status | Air must be turn OFF. Program Step |
Rod Position - Check
- Check the position of the Rod when the Cylinder is in retracted mode. The rod must then not protrude into the cap chute and must only tangent the surface inside the cap chute. If not, adjust the distance A. See Procedure-Section Cap Chute Cylinder Unit - Assemble.

Rod in retracted cylinder mode.
- Rod
- Cylinder
Cap Chute Cylinder Unit - Assemble
- Fasten the Cylinder to the Bracket with the Nut.
- Screw the Nut on the Piston rod in position A that applies when the Piston rod is fully retracted into the Cylinder.
- Tighten the Rod against the Nut so that they become fixed in position A on the Piston rod.
- Install the two Push-in L-fitting on the Cylinder.

A=8 mm
- Rod
- Nut
- Nut
- Piston rod
- Cylinder
- Push-in L-fitting
- Bracket
Bushing - Check
| Equipment Status | Air must be turn OFF. Program Step |
- Check that the correct Bushing are installed on the cap transfer.

- Bushing
Cap Loading Piston, Template, Setting - Check
| Equipment Status | Air must be turn OFF. Program Step |
- Check that the latest version of the cap Loading piston with round heel is installed.

- Loading piston
- Check that the correct cap loading piston Setting template is used.

- Setting template
- Check that distance A for the cap Loading piston is 69 mm. If distance A needs to be adjusted, set it according to Procedure Screw Cap Transfer - Set Rear Position of the Cylinder.

A = 69 mm
- Loading piston
- Check that the Spring is not broken and has no missing pieces.

- Spring
Cap Holder, Position Template - Check
| Equipment Status | Air must be turn OFF. Program Step |
- Check that you have the correct Cap holder and the correct Setting template installed.

- Cap holder
- Setting template
Cap Chute Hatch Setting - Check
| Equipment Status | Air must be turn OFF. Program Step |
- Check that the hatches are closed and that nothing is stuck behind them.
- Check that the Cap chute is mounted correctly into the cap loading Housing to avoid gaps.Note: If one hatch is slightly open or the chute is mounted the wrong way, the cap queue goes down into the drain hole, and the cap position in the Y changes its position slightly down. If the cap position changes, the cap flow is disturbed, which prevents the caps from being fed equally into the two chutes.

- Cap chute
- Housing
Cap Chute Quality - Check
| Equipment Status | Air must be turn OFF. Program Step |
- Check that the parallelism of the Cap chute is 17 mm.


- Cap chute
Cap Quality - Check
- Check the cap ovality as shown in the illustration. The cap shape can be oval, but the diameter cannot be greater than 44.5 mm.
HC Output and Temperature Sensors - Check
Sometimes capping problems occur because of heating problems or deformed necks.- On the TPOP, check the power output to the heating elements in the HC. If there is a difference between 1:1 and 1:2, check the position of the temperature sensors.Note: It can happen that the temperature sensors slide out of position, so the power goes up when the equipment tries to keep the correct temperature.Power output should be approximately 50%.
Lower Forming Tube/Plate - Check
| Equipment Status | Air must be turn OFF. Program Step |
- Check that the Plate is correctly mounted and is in contact against the CAU frame. If the Plate is not mounted correctly, it causes high cap waste.

- Plate
C38 Kit - Check
- Check the latest SPC (SPC-3592746-XXXX) that you have all the correct C38 kit parts.
How to Understand Cap-Related Waste
There are two types of cap-related waste:For camera waste, it is important to differentiate ghost waste from tilted caps:- Ghost waste occurs due to a faulty camera setting.
- Tilted caps occur due to heat problems in the top, or misalignment in the CAU.
For FM waste, see Section How to Understand Cap Waste in FM.How to Understand Cap Waste in FM
Broken caps on the sprue box cause wasted packages without caps. Broken caps are caps that have been smashed in the cap loading area. The caps are smashed because they have been in the wrong position (not all the way down or fallen) during the cap loading sequence.Reasons for broken caps:- The cap hatches or cap chutes are not set correctly causing lack of cue pressure, which makes the caps fall in the cap loading position. See Procedure Cap Chute Hatch Setting - Check.
FAQ
- Why is the cap sorter too slow?
- The cap sorter could be too slow because the wrong settings can have been chosen on the TPOP.
- Why do caps get stuck in the cap trap right after the sorter?
- The edges in the cap trap are sharp.
Frame - Set Sprue Level Photocell
| Equipment Status | Program Step |
Check the sprue level photocell
- Make sure that the Photocell and the Reflector are clean.
- Make sure that the Photocell reads towards the Reflector and that the green Green LED on the Photocell is lit
- Interrupt the beam and make sure that both Green LED and Orange LED lights up. If not, set the photocell.
- Photocell
- Reflector
- Green LED
- Orange LED
Set the sprue level photocell
- Adjust the position of the Photocell so it is reading towards the Reflector.
- Set the photocell to L (light mode) with the Screw.
- Set the Screw to MAX.
- Photocell
- Reflector
- Screw
- Screw
Light Fixture - Change Lamp
| Equipment Status | Power must be turn OFF.
|
Hazardous VoltageThe main power supply disconnector must be switched off and secured with a lock before changing the light fixture.Will shock, burn or cause death.
- Loosen the Wing nut to remove the Light fixture.
- Remove the Screw.
- Slide out the lamp from the light fixture.
- Disconnect the Electrical connection.
- Change the lamp and assemble in reverse order.

- Wing nut
- Light fixture
- Screw
- Electrical connection
Connection Box - Set Fibre Optic Amplifier
| Equipment Status | Program Step |
- Run 2 sleeves into the magazine so that the fibre optics reads towards the sleeves.
- Set the Amplifier according to:
- Press and hold the Teach-In button button until the green LED blinks 3 times shortly and then release the button.
- Check that both the green and orange LED are lit.
- Set the Mode switch to RUN.

- Amplifier
- Delay switch
- Light switch
- Mode switch
- Teach-In button
Pneumatic Panel - Change Filter Insert (Festo, Mecman)
| Equipment Status | Program Step |
Valid for FestoThe Reservoir has a bayonet coupling.- Twist the Reservoir to the left.
- Pull the Reservoir down.Note: If the water level is above the automatic Drain valve, the drain valve is faulty. Replace if necessary.
- Clean the Reservoir with mild detergent and water.
- Unscrew and change the filter.
- Install the Reservoir.

- Reservoir
- Drain valve
Valid for MecmanNote: The filter cup has a Safety notch which must be pressed down before the Filter cup can be removed.- Loosen the Filter cup without removing it.Note: The Filter cup has a bayonet coupling.
- Loosen the filter insert.
- Remove the filter insert and the Filter cup in one piece.
- Change the filter insert.
- Assemble the Filter cup in reverse order.

- Safety notch
- Filter cup
Valve Panel - Change Air Valve (Festo, Mecman)
| Equipment Status | Air must be turn OFF. Program Step STEP ZERO |
| Consumables | Pneumatic Grease: TP No. 90606-4796 |
Valid for FestoNote: This is a general instruction. All valves are changed in the same way.- Remove the two Screw.
- Remove the Cover.

- Screw
- Cover
Valid for Festo- Remove the two Screw.
- Lift out the old Valve.
- Install a new Valve.
- Install the Cover.

- Screw
- Valve
- Cover
Valid for MecmanNote: This is a general instruction. All valves are changed in the same way.- Open the Lid on the new and the old Valve.
- Make sure that the alignment of the Gasket (either slot no.1 or slot no.14) is the same on both valves. If necessary adjust according to the old valve.
- Assemble the Lid.

- Valve
- Lid
- Slot (no.1 or no.14)
- Gasket
Valid for Mecman- When a new valve is assembled, use pneumatic grease on the seals and the O-rings.Note: See also the pneumatic diagrams located in the Laminated Documents for additional information about the pneumatic system.

- Base plate
- Valve body
- Pilot valve
- Pilot valve
- Blanking kit seal
Magazine - Set Home Position
| Equipment Status | Program Step |
| Special Equipment | Zeroing Rod TP No. 2844915 |
- Connect a keyboard to the TPOP.
- Push F4 to open the technical menu.
- Press Servo technical window.
- Press Reset S1 or Reset S2 (depending on production side).
- Press
Exit. - Press
Save on the pop up window. - Exit technical menu.

- Servo technical window
- Reset S1
- Reset S2
- Open the Door.
- Insert the Zeroing rod into the Slot, through the Hole.
- Remove theZeroing rod without disturbing the position of the Magazine.
- Close the Door.
- Step up the machine to air on.Note: An alarm will occur regarding servomotor position fault.
- Reset the alarm.

- Door
- Zeroing rod
- Slot
- Hole
- Magazine
- Push the F4 button to open the technical menu.
- Press Servo technical window.
- Press Calibrate S1 or Calibrate S2 (depending on production side) to execute homing.
- Make sure the Display shows 0.0 alt. 90.0.
- Press
Exit. - Press
Save on the pop up window. - Exit technical menu.

- Calibrate S1
- Calibrate S2
- Display
Servomotor - Change Motor
| Equipment Status | Program Step |
| Special Equipment | Torque wrench |
| Consumables | Loctite 243 |
Valid for: Planetary gear version 1Hazardous VoltageThe electrical supply disconnecting device must be switched off and secured with a lock before changing the servomotor.Will shock, burn or cause death.
- Remove the Electrical connection from the Servomotor.
- Remove the Screw to loosen the Connector.
- Repeat item Reference on the new motor.Note: The connector must be loosened to remove or install the motor. Be careful not to damage the cables between the Connector and the Servomotor.

- Electrical connection
- Servomotor
- Screw
- Connector
- Rotate the magazine until the screws (2 pcs) in the Clamping element are visible through the Hole.
- Loosen the screws (2 pcs) in the Clamping element with an Allen Key.
- Remove the Screw to remove the Servomotor.
- Clean the new Servomotor Shaft with alcohol.
- Clean the contact surface for the Shaft in the Clamping element with alcohol.
- Apply loctite 243 on the Screw.
- Assemble the Servomotor, and tighten the Screw to 22 Nm.
- Tighten the screws for the clamping element crosswise in three steps: first to 3 Nm, then to 6 Nm, and finally to 9.5 Nm.
- Assemble the remaining parts in the reverse order.
- Set home position for the magazine according to:

- Servomotor
- Clamping element
- Hole
- Screw
- Shaft
Valid for: Planetary gear version 2Hazardous VoltageThe electrical supply disconnecting device must be turned off and secured with a lock before changing the servomotor.Will shock, burn, or cause death.
- Remove the Cable from the Servomotor.

- Cable
- Servomotor
- Remove the Plug.
- Rotate the Magazine until the screw in the clamping element is visible through the Hole.
- Loosen the screw in the Clamping element with an allen key.
- Remove the Screw, and remove the Servo motor.

- Plug
- Magazine
- Hole
- Clamping element
- Screw
- Servo motor
- Clean the Shaft with alcohol.
- Clean the Contact surface for the Shaft with alcohol.
- Apply Loctite 243 on the Screw.
- Install the Servo motor, and tighten the Screw to 22 Nm.
- Tighten the screw in the clamping element to 14 Nm with an allen key.
- Install the Plug.

- Plug
- Shaft
- Contact surface
- Screw
- Servo motor
Hazardous VoltageThe electrical supply disconnecting device must be turned off and secured with a lock before changing the servomotor.Will shock, burn, or cause death.
- Install the Cable on the Servo motor.

- Servo motor
- Cable
Servomotor - Change Planetary Gear
| Equipment Status | Program Step |
| Consumables | Loctite 243 |
Valid for: Planetary gear version 1- Remove the box according to:
- Loosen the Nut, and remove the Chute.

- Nut
- Chute
- Remove the Screwand the Washer.
Heavy equipment.Handle the magazine with care. Make sure that two persons work together to handle the weight.The magazine is heavy and can cause personal injury and damage to equipment.
Remove the Magazine.
- Screw
- Washer
- Magazine
- Remove the motor according to:
- Remove the Screw.
- Remove the Planetary gear.
- Assemble the new Planetary gear with the Screw.
- Assemble the motor according to:
- Set home position for the magazine according to:

- Screw
- Planetary gear
Valid for: Planetary gear version 2- Remove the box according to:
- Loosen the Nut, and remove the Chute.

- Nut
- Chute
- Remove the Screw.
Heavy equipment.Handle the magazine with care. Make sure that two persons work together to handle the weight.The magazine is heavy and can cause personal injury and damage to equipment.
Remove the Magazine.
- Screw
- Magazine
- Remove the motor according to:
- Remove the Screw.
- Remove the Motor bracket.

- Screw
- Motor bracket
- Remove the Screw.
- Remove the Planetary gear.

- Screw
- Planetary gear
- Remove the Screw.
- Remove the Ring from the Planetary gear.
- Install the Ring on the new Planetary gear.

- Planetary gear
- Screw
- Ring
- Install the Planetary gear in the frame .
- Fit the Screw, and tighten them by hand.
- Use an allen key to tighten the Screw crosswise.

- Screw
- Planetary gear
- Install the Motor bracket on the Planetary gear.
- Make sure that the Hole is facing outwards.
- Apply Loctite 243 on the Screw.
- Install and tighten the Screw to 4.55 Nm.

- Screw
- Motor bracket
- Planetary gear
- Hole
- Assemble the motor according to:
- Set home position for the magazine according to:
Drive Unit - Set Linear Unit
| Equipment Status | Program Step |
- Loosen the Screw.
- Set the distance A between the edge of the Linear unit and the Bracket.
- Make sure that the Linear unit rests against the two Guide pin and tighten the Screw. Check with a 0.1mm feeler gauge.
- With the magazine in zero position, make sure that the CAU stripper moves freely. If not, set the CAU stripper. See Procedure CAU Stripper - Set.
- Set the home position for the drive unit. See Procedure Drive Unit - Set Home Position.

A = 230 ±1 mm
- Screw
- Linear unit
- Bracket
- Guide pin
- CAU stripper
Drive Unit - Set Home Position
| Equipment Status | Program Step STEP ZERO |
- Disconnect the Electrical Connection from the Motor.
- Connect the Electrical Connection to the Motor.
- Step up the machine to Program step tank filling.
- Reset upcoming alarms.
- The drive Linear Unit now performs a home search (the CAU stripper moves slowly against the Stop plate).

- Electrical Connection
- Motor
- Linear Unit
- Stop plate
Drive Unit - Set Capping Position
| Equipment Status | Program Step HEATING |
Note: This procedure is only valid when Controlled Capping is deactivated.Note: It is important that both production sides of the machine are stepped down to HEATING or lower for this setting to take effect.- Connect a keyboard to the TPOP.
- Step the machine up to Program step production.
- Produce two packages.
- Wait until the packages have passed through the machine.
- If the packages were transferred out of the machine the normal way through the outfeed conveyer, see Section Set Capping Position.
- If the packages have no screw caps and were thrown out of the machine after the package section, see Section Set Cassette Position.Note: Packages can be thrown out of the machine for other reasons, but if they have no screw caps, it is likely that the capping position for the drive unit is set wrong.
Set Capping Position
- Push the F4 button to open
Technical menu. - Press CAU technical window.
- Press Capping position S1 or Capping position S2, depending on production side to activate it.
- Press Enable Increase/Decrease.
- Use Decrease to reduce the value for Capping position S1 or Capping position S2 by 0.5 and displace the capping position backward.
- Press Exit and press save.
- Repeat items Reference to Reference and continue to reduce the value for Capping position S1 or Capping position S2 in steps of 0.5, until the packages get thrown out of the machine after the package section. Then add 1.0 to the value for Capping position S1 or Capping position S2 and the setting is finished.Note: When the packages are thrown out of the machine after the package section, it indicates that the screw cap is not correctly attached.
- CAU technical window
- Capping position S1
- Capping position S2
- Enable Increase/Decrease
- Decrease
- Increase
- Exit
Set Cassette Position
- Push the F4 button to open
Technical menu. - Press CAU technical window.
- Press Cassette position S1 or Cassette position S2, depending on production side, to activate it.
- Press Enable Increase/Decrease.
- Use Increase to add 0.5 to the value for Cassette position S1 or Cassette position S2 and displace the capping position forward.
- Press Exit and press
save. - Repeat items Reference to Reference and continue to add to the value for Cassette position S1 or Cassette position S2 in steps of 0.5 until the packages are transferred out of the machine through the outfeed conveyer. Then the setting is finished.Note: When the packages are transferred out of the machine through the outfeed conveyer, it indicates that the setting is correct.
- CAU technical window
- Enable Increase/Decrease
- Decrease
- Increase
- Exit
- Cassette position S1
- Cassette position S2
Drive Unit - Change Motor
| Equipment Status | Program Step HEATING |
Hazardous VoltageThe main power supply disconnector must be turned off off and secured with a lock before changing the servomotor.Will shock, burn or cause death.
- If the Connector points according to illustration B, continue with item f). If not, continue with item b).
- Remove the Screw.
- Turn the Connector 180°.
- Make sure that the Rubber sealing is fitted correctly.
- Assemble the Connector with the Screw.

- Screw
- Connector
- Rubber sealing
- Motor
- If there is a Key on the Motor, remove it.
- Change the motor according to instructions in Procedure:

- Motor
- Key
Drive Unit - Set Stop Plate
| Equipment Status | Program Step Step Zero |
- Insert the Nut in the lower trail. Slide it to the middle of the Linear unit.
- Assemble the Stop plate and the Screw in the Nut.Note: To keep the correct position, insert a cable tie under the nuts.

- Nut
- Stop plate
- Screw
- Linear unit
- Position the Set screw so that about the same distance sticks out on both sides of the Stop plate.
- Assemble the Nut to the Set screw.

- Stop plate
- Set screw
- Nut
- Pull the Stripper back against the Station bracket.
- Put a 1-mm feeler gauge between the Stripper and the Station bracket.Note: The distance A can differ between the inner and outer side of the stripper. Make sure that the smallest distance is A.

A = 1 ±0.1mm
- Stripper
- Station bracket
- Pull the Stop plate forward against the Stripper.
- Tighten the Screw to secure the position of the Stop plate.
- Remove the feeler gauge.

- Stop plate
- Screw
- Linear unit
- Stripper
- Pull the Stripper forward, away from the Stop plate.
- To check the distance A, rotate the Magazine and repeat items Reference to Reference. Rotate 90° at a time. Check all four magazine positions.If the distance A<1 ±0.1mm for any of the positions, repeat items Reference to Reference for the position with the smallest distance A.Note: The check procedure is done to ensure that the Stripper does not hit the Magazine during production.

- Stop plate
- Stripper
- Magazine
Check the setting:- Move the Stripper forward and backward.
- Check that the distance A, between the Stripper and the Station bracket, is still correct.
- If necessary, fine-tune the setting by loosening the Nut, adjusting the Set screw, and tightening the Nut again.
- Repeat from item Reference until the correct measurement is achieved.
- If not following the Setting Sequence CAU, set home position. See Procedure Drive Unit - Set Home Position.

A = 1 ±0.1 mm
- Set screw
- Nut
- Stripper
- Station bracket
Drive Unit - Change Gear Box
| Equipment Status | Program Step HEATING |
Note: This instruction is only valid for machines with the updated linear unit.- Disconnect the Electrical connection.
- Remove the Screw for the CAU stripper.

- Electrical connection
- Screw
- CAU stripper
- Remove the Screw and the Clamping element.
Risk of damage to the drive unit.Handle the drive unit with care.The drive unit is heavy and has an uneven centre of gravity.
Loosen the Screw and remove the Drive unit.
- Screw
- Clamping element
- Screw
- Drive unit
- Remove the Screw.
- Move the Slide until the Screw is visible through the Hole.
- Loosen the Screw.
- Remove the Screw and remove the Motor from the Linear unit.

- Screw
- Slide
- Screw
- Hole
- Screw
- Motor
- Linear unit
- Remove the Screw.
- Remove the Screw.
- Remove the Gearbox.
- Install a new Gearbox.

- Screw
- Screw
- Gearbox
- Make sure that the Slit in the Coupling is positioned at the angle A from the Screw.
- Fit the Hex key in the Screw to prevent the Coupling from rotating.

A = 90º
- Screw
- Hole
- Coupling
- Slit
- Hex key
- Assemble the Motor to the Linear unit.
- Tighten the Screw.
- Tighten the Screw to a torque of 9.5Nm.
- Tighten the Screw.

- Screw
- Screw
- Screw
- Motor
- Linear unit
- Assemble in reverse order.
- Set the linear unit. See Procedure Drive Unit - Set Linear Unit.
- Set the CAU stripper. See Procedure CAU Stripper - Set.
- Set the stop plates. See Procedure Drive Unit - Set Stop Plate.
- Step up the machine to Program step tankfilling. Reset upcoming alarms. The Drive unit will now perform a home search (the CAU stripper moves slowly to mechanical stop against the stop plates).
Drive Unit - Lubricate Linear Unit
| Equipment Status | Program Step Step Zero |
| Special Equipment | Grease gun: TP No. 3366407-0000 |
| Consumables | Grease 1607031-0000 |
Note: Valid for Linear Units 90610-4498 and 90610-4497.- Use a Grease gun and grease the Nipple of the Linear Unit every 1000 hours with 2,8 cm3 grease.Note: Remove surplus lubrication.

- Grease gun
- Linear Unit
- Nipple
CAU Stripper - Set
| Equipment Status | Power must be turn ON. Program Step step zero |
| Special Equipment | Position Template TP No. 2844893-0200 Position Template TP No. 2844892-0000 (Base) Position Template TP No. 2875379-0000 (Midi) Position Template TP No. 2931921-0000 (Mini STD) Position Template TP No. 3440368-0000 (Mini V) Position Template TP No. 3021657-0000 (Base) Position Template TP No. 3021658-0000 (Midi) Position Template TP No. 3531804-0000 (Midi AW) Position Template TP No. 3017554-0000 (Mini) |
Note: The illustrations show bottom format Base. Information about exceptions is provided in text and illustrations.- Remove the Screw and the Bracket assembled with stripper fingers.
- Remove the Screw, the Washer, and the Bracket assembled with stripper fingers.

- Screw
- Bracket
- Screw
- Washer
- Bracket
- Put the Bracket assembled with Stripper finger on a flat surface.
- Make sure that all four Stripper finger rest evenly on the surface.
- If adjustment of the Stripper finger is needed:
- Loosen the Screw on the specific stripper finger.
- Hold the stripper finger against the mechanical stops according to the illustration.
- Tighten the Screw.

- Bracket
- Stripper finger
- Screw
- Put the Bracket assembled with Stripper finger on a flat surface.
- Make sure that all four Stripper finger rest evenly on the surface.
- If adjustment of the Stripper finger is needed:
- Loosen the Screw on the specific stripper finger.
- Hold the stripper finger against the mechanical stops according to the illustration.
- Tighten the Screw.

- Bracket
- Stripper finger
- Screw
- Assemble the Bracket with the Washer and the Screw, but do not tighten the Screw.
- Make sure that the Edge are even on both sides. Make sure that the Surface is even with the Surface. Tighten the Screw.

- Screw
- Washer
- Bracket
- Edge
- Surface
- Surface
- Open the Capping station.
- Push the CAU stripper forward as far as possible toward the package section.
- Loosen the Screw.
- Position the Position template including the Rod according to the illustration.
- Push the CAU stripper backward until the Stripper finger reach mechanical stop against the Rod.
- Make sure that all four Stripper finger rest against the Rod. Tighten the Screw. Check with a 0.1-mm feeler gauge.
- Remove the Rod.

- Stripper finger
- Capping station
- CAU stripper
- Position template
- Rod
- Screw
- Loosen the Screw.

- Screw
- Assemble the Position template to the Position template with the Screw. Repeat for both forming tube templates.Note: Mini V is not symmetric and cannot be turned 180 degrees in the forming tubes as for the other templates. To check the stripper alignment, move the Position template to the rear position.

Opening Nallo
- Position template
- Position template
- Screw
- Align the Position template according to the illustration. The Surface of the Position template must be even with the Surface of the capping station.
- Position the CAU stripper according to the illustration.

- CAU stripper
- Position template
- Surface
- Surface
- Not valid for: Package shape Mini VMake sure that the Stripper finger are positioned against the Position template according to the illustration.
- Valid for: Package shape Mini VUse a feeler gauge to set the distance A between the Stripper finger and the Position template according to the illustration.
- Press the Bracket down, toward the Position template. Tighten the Screw.
- Check that all Stripper finger are aligned in height with the Position template. If they are not, adjust according to item Reference to Reference.

Base

Mini V

Mini/Midi
- Screw
- Bracket
- Stripper finger
- Position template
- Remove the Screw and the Stripper finger.Note: This instruction only applies to machine variants that have the Screw and Stripper finger in the standard design.

- Screw
- Stripper finger
- Assemble the Bracket with the Screw, but do not tighten the Screw.

- Screw
- Bracket
Note: The main illustration shows the bottom format BASE. The enlarging shows the different bottom formats.- Pull back the CAU stripper.
- Reposition the Position template according to the illustration. The Surface of the Position template must be even with the Surface of the capping station.

- CAU stripper
- Position template
- Surface
- Surface
- Make sure that the Stripper finger are positioned against the Position template according to the illustration.
- Press the Bracket down, toward the Position template. Tighten the Screw.
- Check that all the Stripper finger are aligned in height with the Position template. If they are not, adjust according to item Reference to Reference.

Base

Midi/Mini
- Screw
- Bracket
- Stripper finger
- Position template
- Remove the forming tube templates assembled with the position templates.
- Close the capping stations.
- Assemble the Stripper finger with the Screw. Make sure that the Mechanical stop on the Stripper finger are tight against the Bracket and tighten the Screw.Note: This instruction only applies to machine variants that have the Screw and Stripper finger in the standard design.
- Set home position.See Procedure Drive Unit - Set Home Position.

- Bracket
- Screw
- Stripper finger
- Mechanical stop
CAU Stripper - Set Capping Reference
| Equipment Status | Air must be turn ON. Program Step AIR ON |
| Special Equipment | Position Template TP No. 2844893-0200 Position Template TP No. 2989790-0000 (Screw Cap O38) Position Template TP No. 3342748-0000 (Screw Cap C38) Position Template TP No. 3738867-0000 (Screw Cap C38 V2) Position Template, TP No. 2844892-0000 (Base) Position Template, TP No. 2875379-0000 (Midi) Position Template, TP No. 2931921-0000 (Mini STD) Position Template, TP No. 3440368-0000 (Mini V) Shaft, TP No. 3389343-0000 (Base) Shaft, TP No. 3389344-0000 (Midi) Shaft, TP No. 3389345-0000 (Mini) Shaft, TP No. 3750183-0000 (Base C38 V2) Shaft, TP No. 3750184-0000 (Midi C38 V2) Shaft, TP No. 3750185-0000 (Mini C38 V2) Setting Template TP No. 2901501-0000 Valve Guide TP No. 90458-2888 |
Risk of crushing.Be careful when activating the cylinder.The air cylinder will move if it is activated by compressed air.
Note: This procedure is only valid when Controlled Capping is activated.- Use a Wrench to lift and hold the Capper unit.
- Put the Setting template in position.
- To achieve fully retracted position, start the capper cylinder with the valve guide.
- G31K1220 for S1
- G31K2220 for S2

- Wrench
- Capper unit
- Setting template
Make sure that it is possible to adjust the Stripper Capping reference on the TPOP. To save the value for the Stripper actual position, it must be close to the current Stripper Capping reference.- If the Stripper Capping reference square is marked grey, adjust the stripper so that the Stripper actual position value is closer to the current Stripper Capping reference. See the following illustration.

- Stripper Capping reference
- Stripper actual position
- Position the Position template and Shaft.
- Adjust the height with the Screw until the Position template and the Cap holder are centred.
- Slide the Position template forward until they enter the Cap holder.
- Gently push the Stripper fingers toward the Shaft. Make sure that there are no gaps between the Stripper fingers and the Shaft, and between the Position template and the Cap holder.

- Cap holder
- Screw
- Position template
- Shaft
- Press Stripper Capping reference.Note: If the Stripper Capping reference square is marked grey, see item .
- Copy the value of Stripper actual position to Stripper Capping reference by pressing Save.
- Press Exit and press
Save. 
- Stripper Capping reference
- Stripper actual position
- Save
- Exit
- Remove the valve guide.
- Release the capper cylinder from fully retracted position.
- Use a Wrench to hold the capper unit.
- Remove the Setting template.
- Lower the capper unit with the Wrench.

- Wrench
- Setting template
Capping Station - Check Fibre Optic
- Make sure that the Fibre optics and holes (see pointer arrows) are clean.
- Check that only the Green LED on the is lit.
- Interrupt the beam and check that both the Green LED green and Orange LED on the Fibre optic amplifier are lit. If necessary:

- Fibre optics
- Green LED
- Orange LED
- Fibre optic amplifier
Capping Station - Set Stop Plate
| Equipment Status | Program Step Heating |
- Loosen the Nut.
- Set the distance A for the Stop plate.
- Tighten the Nut.
| Bottom format | A (mm) |
| Base | 25±0.2 |
| Midi | 21±0.2 |
| Mini | 23±0.2 |

Base

Mini and Midi
- Nut
- Stop plate
Capping Station - Set to Package Section
| Equipment Status | Program Step |
- Remove the Screw to remove the Template from the Setting template.
- Assemble the Position template to the Setting template with the Screw.

- Screw
- Template
- Setting template
- Screw
- Position template
- Step the machine up to tankfilling.
- Inch the machine to sector value 195.
- Open the Forming tube and position the Setting template according to illustration.

- Cassette
- Capping station
- Forming tube
- Setting template
- Slide the Position template into the Cassette.
- Make sure that the Position template does not touch the Cassette in any position.
- If adjustment is needed see:

- Position template
- Cassette
- Slide the Position template to the bottom of the Cassette.
- Make sure that the Position template does not touch the Cassette in any position.
- If adjustment is needed see:
- Repeat the items i) to k) for both forming tubes.
- If further adjustment is needed, use a package sleeve instead of the setting template and adjust as earlier according to:

- Position template
- Cassette
Screw Cap Transfer - Check Leaf Spring
| Equipment Status | Program Step HEATING |
- Remove the box. See Procedure Box - Remove.
- Remove the Screw, the Washer, the Bracket, and the Guide bearing.
- Check the Bracket for wear, and change if necessary.
- Remove the Screw and the Washer.
- Remove the Loading piston by compressing the spring inside.

- Screw
- Washer
- Bracket
- Guide bearing
- Screw
- Washer
- Loading piston
- Remove the Screw and the Washer to remove the Bushing.
- Remove the Leaf spring.
- Inspect the Leaf spring.
- Check if there are missing pieces or if it is broken.
- Check dimensions. See item Reference.
- If necessary, change the Leaf spring before assembling in the reverse order.

- Screw
- Washer
- Bushing
- Leaf spring
- Check dimensions A and B of the fingers of the Leaf spring.Note: If necessary, set the dimensions A and B of the fingers of the Leaf spring.

A = 2 mm
B = 7 mm
- Leaf spring
Screw Cap Transfer - Set Parallelism
| Equipment Status | Program Step AIR ON |
| Special Equipment | Valve Guide TP No. 3520946-0000, Valid for Mecman Setting Template TP No. 2901501-0000 |
Risk of crushing.Be careful when activating the cylinder.The air cylinder moves if it is activated by compressed air.
Note: Before setting the screw cap transfer, it is important that the capper unit is set correctly according to Procedure .- Use a Wrench to lift and hold the Capper unit.
- Remove the Screw in the Setting template TPNo.2901501-0000.
- Put the Setting template in a flat, 20mm, position to achieve the correct position of the screw cap holders.

- Capper unit
- Setting template
- Screw
- Wrench
- Activate the capping cylinder valves to push the screw cap holders in loading position. To activate the valves, see Procedure Pneumatic Valves - Manual Override.
- G31K1220 for S1
- G31K2220 for S2
- Hold the Loading piston against the Screw cap holder.
- Check that both Loading piston are aligned against the Screw cap holder to achieve parallelism.

- Loading piston
- Screw cap holder
- Tighten the three Screw while gently pushing the Cylinder forward by hand.
- Assemble the three Plug.

- Cylinder
- Screw
- Plug
- When the screws are tightened, push the cylinder forward again. Use a Feeler gauge to check that both Loading piston are still aligned against the Screw cap holder.Note: A 0.1mm feeler gauge should not be able to enter on either side.
- Deactivate the pneumatic valves. See Procedure Pneumatic Valves - Manual Override.
- G31K1220 for S1
- G31K2220 for S2
- Remove the setting template from the screw cap lift.

- Loading piston
- Screw cap holder
- Cylinder
- Feeler gauge
Screw Cap Transfer - Set Overloading
| Equipment Status | Program Step AIR ON |
| Special Equipment | Valve Guide TP No. 3520946-0000. Valid for Mecman. Setting Template TP No. 2901501-0000 |
Risk of crushing.Be careful when activating the cylinder.The air cylinder moves if it is activated by compressed air.
This operation is done to ensure a correct overloading of the loading pistons. Too little overloading makes the screw caps fall out of the screw cap holders, too much overloading breaks the capping cylinder.- Before performing this setting, make sure that the cap lift is in cap transfer position. See Procedure Screw Cap Lift - Set End Positions.
- Activate the capping cylinder valves to push the screw cap holders in loading position. To activate the valves, see Procedure Pneumatic Valves - Manual Override.
- G31K1220 for S1
- G31K2220 for S2
- Load a screw cap in the screw cap holder manually.
- Push the screw cap transfer unit forward and load screw caps into the screw cap holders.
- Activate the transfer cylinder valves to put the loading pistons in their loading position. To activate the valves, see Procedure Pneumatic Valves - Manual Override.
- G31K1217 for S1
- G31K2217 for S2
- Rotate the screw cap holders to the left, gently by hand, until the heels in the screw caps are aligned with the notches on the Loading piston.Note: This step is performed to ensure that the over travel distance will be correct. If the notches on the loading piston and the heels in the screw caps are interfering in the wrong way, the over travel distance will be incorrect.
- Use a feelergauge to check the distance A between the Loading piston and the Bracket.
- To set the distance A, loosen the Lock nut and adjust the position of the Bracket with the Adjustment screw and tighten the Lock nut.

A = 2 ±0.5 mm
- Loading piston
- Bracket
- Adjustment screw
- Lock nut
- The sensor is activated when the cap transfer unit is in loading position. If the sensor is not activated, adjust the sensor.Note: The sensor is only activated when the yellow LED is lit.
- Loosen the Screw on the Sensor.
- Slide the Sensor to find the interval where only the yellow LED light on the sensor is lit. Yellow and red LED light at the same time indicates that the sensor is outside the sensitivity interval.
- Set the Sensor in the middle of this interval and tighten the Screw.
- Deactivate the pneumatic valves. See Procedure Pneumatic Valves - Manual Override.
- G31K1220 for S1
- G31K1217 for S1
- G31K2220 for S2
- G31K2217 for S2

- Screw
- Sensor
Screw Cap Transfer - Set Valve
| Equipment Status | Program Step HEATING |
- Make sure that the Throttle check valve on the transfer cylinder is fully opened.

- Throttle check valve
Screw Cap Transfer - Change Rotation Stop and Piston Spring
| Equipment Status | Program Step heating |
| Consumables | Loctite 243, TP No. 344431-0000 |
Change both the rotation stop and the spring at the same time even if only one of them needs to be changed. See Procedure Screw Cap Transfer - Check Rotation Stop and Piston Spring in the MM.- Remove the box. See Procedure Box - Remove in the MM.
- Remove the two Screw, the two Washer, and the Bracket.
- Remove and discard the Rotation stop.

- Screw
- Washer
- Bracket
- Rotation stop
- Remove the Screw and the Washer.
- Compress the spring inside the Loading piston with the Shaft to be able to get the loading piston out.

- Screw
- Screw
- Washer
- Loading piston
- Shaft
- Remove the Shaft.
- Remove and discard the Spring.

- Loading piston
- Shaft
- Spring
- Apply Loctite 243 on the fastening Screw (see arrow).
- Assemble in the reverse order with the new rotation stop and new spring.

- Screw
Screw Cap Transfer - Set Rear Position of the Cylinder
| Equipment Status | Program Step HEATING |
- Pull back the Cap Transfer Unit.
- Measure the distance A for the Pusher.
- If necessary, adjust the Setting Screw to set the distance A.

A = 69 ±1.0 mm
- Cap Transfer Unit
- Pusher
- Setting Screw
Screw Cap Sorter - Check Photocell
| Equipment Status | Program Step Program Step |
- Make sure that the Photocell reads towards the Reflector.
- Make sure that the Photocell and the Reflector are clean.
- Check that the Green LED, on the Photocell lights.
- Interrupt the beam and make sure that both Green LED and Orange LED lights up. If not, set the photocell according to:

- Photocell
- Reflector
- Green LED
- Orange LED
Screw Cap Sorter - Set Photocell
| Equipment Status | Program Step Program Step |
- Set the Photocell to D (dark mode), with the Screw.
- Set the Screw to MAX for the Photocell.
- Check the function according to:

- Photocell
- Screw
- Screw
Screw Cap Sorter - Set Valve
| Equipment Status | Program Step HEATING |
- Empty the system on screw caps, including the CSU and the screw cap sorter. See the OM.
- If equipped with one valve, close the Valve.If equipped with two valves, close the Valve and the Valve.
- Put one screw cap in the Return pipe.
- Step up to TANKFILLING.
- Open the Valve about seven turns.
- If equipped with two valves, open the Valve about four turns.
- Test the screw cap sorter.If necessary, adjust the airflow further.

One valve

Two valves
- Return pipe
- Valve
- Valve
Screw Cap Sorter - Change Motor
| Equipment Status | Power must be turn OFF.
|
Hazardous VoltageThe main power supply disconnector must be switched off and secured with a lock before changing the servomotor.Will shock, burn or cause death.
- Disconnect the Electrical connection from the Motor.
- Remove the Screw and the Washer.
- Remove the Motor.
- Change the Key if necessary.
- Assemble the new motor in reverse order.

- Electrical connection
- Motor
- Key
- Washer
- Screw
Screw Cap Sorter - Change Photocell
| Equipment Status | Program Step Program Step |
- Disconnect the Electrical connection and remove the Screw.
- Change the Photocell and assemble in the reverse order.
- Set the new Photocell according to:

- Electrical connection
- Screw
- Photocell
Screw Cap Sorter - Change Leaf Spring
| Equipment Status | Program Step Program Step |
Note: Be very careful not to drop any screws, washers or other items inside the screw cap sorter during this procedure. Small loose items inside the screw cap sorter can end up inside produced packages.- Switch OFF the main power supply disconnector for the CSU.
- Empty the screw cap sorter from screw caps according to OM.
- Open the Bottom plate.
- Remove the Screw and the Washer to remove the Basic plate that the leaf spring is attached to.
- Lift out the basic plate with the leaf spring from the screw cap sorter.

- Bottom plate
- Screw
- Washer
- Basic plate
- Remove the Screw from the Bracket to remove the Leaf spring.
- Change the leaf spring and assemble in the reverse order.
- Switch ON the main power supply disconnector for the CSU.

- Basic plate
- Screw
- Bracket
- Leaf spring
Chute - Check Photocell
| Equipment Status | Program Step Program Step |
- Empty the Chute from screw caps according to OM.
- Remove the Lid.
- Make sure that the Photocell is clean.
- Check that the Green LED, on the Photocell lights.
- Interrupt the beam and make sure that both Green LED and Orange LED lights up. If not, set the photocell according to:
- Assemble the Lid.

- Chute
- Lid
- Photocell
- Green LED
- Orange LED
Chute - Set Photocell
| Equipment Status | Program Step Program Step |
- Set the Photocell to D (dark mode), with the Screw.
- Set the Screw to MAX for Photocell.
- Check the function according to:

- Photocell
- Screw
- Screw
Chute - Set Valve
| Equipment Status | Program Step HEATING |
- Close the Valve.
- Open the Valve approximately 4 turns.
- Test the chute.If necessary, adjust the airlow further.

- Valve
- Chute
Chute - Set Direction Guide and Plate
| Equipment Status | Program Step Program Step |
- Loosen the Nut.
- Adjust the Direction guide to achieve the distance A.
- Tighten the Nut.
- Loosen the Nut.
- Adjust the Plate to achieve the distance B.
- Tighten the Nut.

A = 60 ±1 mm
B = 4.5 ±0.5 mm
- Nut
- Direction guide
- Nut
- Plate
Chute - Set Direction Guide and Plate
| Equipment Status | Program Step Heating |
- Loosen the Nut.
- Adjust the Direction guide to achieve the distance A.
- Tighten the Nut.

A = 135 mm
- Nut
- Direction guide
Chute - Set Chute towards Cap Transfer House
| Equipment Status | Program Step Program Step |
There is a shelf at the bottom of the cap transfer house that the chute needs to lie on. If it falls off this, the space for the caps to pass will be too small. This will cause the machine to stop.- Loosen the Screw.
- Loosen the Two screws.
- Loosen the Two screws.
- Loosen the Screw.
- Loosen the Screw.

- Screw
- Two screws
- Two screws
- Screw
- Screw
- Make sure that the Chute rests on the Shelf.

- Chute
- Shelf
- Tighten the Screw.
- Tighten the Two screws.
- Tighten the Two screws.
- Tighten the Screw.
- Tighten the Screw.

- Screw
- Two screws
- Two screws
- Screw
- Screw
Chute - Set Lid Fastener
| Equipment Status | Program Step Program Step |
- Adjust the Fastener by loosening the Nut and adjusting with the Screw.

- Fastener
- Nut
- Screw
- Adjust the Fastener so that there is no gap between the Chute and the Lid.
- Make sure that the Lid can be easily removed by hand for cleaning.

- Fastener
- Chute
- Lid
Chute - Check Cap Chute Cylinder
| Equipment Status | Program Step STEP ZERO |
- Check the position of the Rod when the Cylinder is in the retracted mode. The rod must be tangent to the surface inside the cap chute and must not protrude into the cap chute. If not, adjust the distance A.
- Loosen the Nut.
- Adjust the Nut to distance A.
- Tighten the Rod against the Nut.

A = 8 mm
- Rod
- Nut
- Cylinder
- Check the extend-retract motion of the Rod and the Cap Chute Cylinder.Use the manual override function to operate the Pilot Valves (on the Pneumatic Unit) that control the motion of the Cylinder.For the manual override function, see the procedure Pneumatic Valves - Manual Override in the MM.Note: On S1 (S2), the pilot valve G31K1217(G31K2217) extends and the pilot valve G31K1218(G31K2218) retracts the Cylinder G31M1343(G31M2343).
Discharge Chute - Set Pneumatic Cylinder
| Equipment Status | Program Step |
It is important that the hatch is completely closed in its end position. A gap between the chute and the hatch can create an edge that the caps can get stuck on.- Use the Adjusting nut to adjust the end position of the Cylinder. Make sure that the Hatch is tight against the Chute.

- Adjusting nut
- Cylinder
- Hatch
- Chute
Screw Cap Applicator Unit
Capper Unit - Check Timing Belt
| Equipment Status | Program Step |
- Turn the Timing belt and check that edges of the belt not are worn or frayed, and that it runs(is guided) correctly over the pulleys.
- Check the belt tension with a tension meter.
- If necessary change according to:

- Timing belt
Capper Unit - Check Ball Bearings
| Equipment Status | Program Step |
- Loosen the Nut to release the tension in the timing belt.
- Turn the Ball bearing to make sure they are in good condition and have no signs of damage or wear. No play is allowed.
- If necessary change according to:
- Set the timing belt according to:

- Nut
- Ball bearing
Capper Unit - Check Upper Sprocket Ball Bearing
| Equipment Status | Program Step |
- Check the Ball bearing for damage and wear.
- If necessary change according to:

- Ball bearing
Capper Unit - Check Cylinder
| Equipment Status | Program Step |
- Hold the Servomotor and move them up and down to detect if there is a gap in the Capper cylinder. Make sure that the Capper cylinder moves smoothly by moving it back and forth.
- If there is a gap in the Capper cylinder, or it does not move smoothly, change it according to:

- Servomotor
- Capper cylinder
Capper Unit - Basic Set
| Equipment Status | Program Step AIR ON |
| Special Equipment | Position Template TP No. 2844893-0200 (assembly) Position Template TP No. 2989790-0000 (Screw Cap O38) Position Template TP No. 3342748-0000 (Screw Cap C38) Position Template TP No. 3738867-0000 (Screw Cap C38 V2) Setting Template TP No. 2901501-0000 Valve Guide TP No. 90458-2888 |
Preparations
- Open the Capping station.
- Remove the Servomotor together with the Spacer and the Wheel according to Procedure Capper Unit - Change Servomotor.
- Loosen the Screw.
- Remove the Spring.

- Capping station
- Spring
- Screw
- Wheel
- Spacer
- Servo motor
Risk of crushing.Be careful when activating the cylinder.The air cylinder will move if it is activated by compressed air.
- Loosen the Screw.
- To achieve fully retracted position, start the Capper cylinder with the valve guide:
- G31K1220 for S1 or G31K2220 for S2
- Make sure that distance A is according to the illustration.
- If adjustment is needed, remove the valve guide to release the pressure in the Capper cylinder.
- Loosen the Lock nut. Then adjust the Adjustment screw with a 6-mm hex key.Repeat the items Reference to Reference until distance A is achieved.
- When distance A is correct, tighten the Lock nut while the Capper cylinder is activated with the valve guide in fully retracted position. Keep the Capper cylinder activated.

A = 4 mm
- Screw
- Lock nut
- Adjustment screw
- Capper cylinder
- Loosen the Screw.
- Push the Capper unit downward to mechanical stop.
- Tighten the Screw with the Capper unit in this position.
- Loosen the Screw.

- Screw
- Screw
- Capper unit
Set Capper Unit Parallelism
- Use a Wrench to lift and hold the Capper unit.
- Put the Setting template in position.
- Position the Forming tube template.
- Put the Rod in position.
- Adjust the height with the Screw until the Forming tube template and the Screw cap holder are centred.
- Slide the Forming tube template forward until they enter the Screw cap holder.Note: If it is impossible to fit the forming tube templates in the screw cap holders, loosen the Screw keeping the screw cap holder in lowest possible position. Fit the Forming tube template in the Screw cap holder. If necessary, adjust the height with the Screw. Then tighten the Screw.

- Wrench
- Capper unit
- Setting template
- Forming tube template
- Rod
- Screw cap holder
- Screw
- Screw
- Push and hold the entire Capper unit as close as possible to the Capping station.
- Make sure that the gaps A are zero between the Forming tube template and both of the Screw cap holder.
- With the Capper unit held in this position, tighten the Screw.

- Forming tube template
- Screw cap holder
- Capper unit
- Capping station
- Screw
- Loosen the Screw.
- Measure the distance B between the Bracket and the Beam.
- Adjust the height of the Setting template with the Screw until the distance B is reduced by 1 mm compared to the measurement under item Reference.
- Make sure that the Forming tube template are aligned against and rest against the capping station.
- Tighten the Screw with the capper unit in this position.Note: These steps are performed to make sure that the Screw end up in the middle of their setting holes.

- Setting template
- Forming tube template
- Screw cap holder
- Screw
- Screw
- Bracket
- Beam
Set Bridge and Cylinder End Positions
Risk of crushing.Be careful when activating the cylinder.The air cylinder will move if it is activated by compressed air.
Risk of damage to equipmentNever set the gap
A, illustrated under
Preparations, to less than 3 mm. If the gap is smaller, there is a risk of damage to the equipment.
- Close a Capping station.
- Slide the Forming tube template forward until the Rod stops mechanically against the Capping station.
- Make sure that there is no gap between the Forming tube template and both of the Screw cap holder, with the Rod resting against the Capping station.
- If adjustment is needed, remove the valve guide to release the pressure in the Capper cylinder.
- Loosen the Lock nut. Then adjust the adjustment Screw with a 6-mm hex key.

- Capping station
- Forming tube template
- Rod
- Screw cap holder
- Lock nut
- Screw
- Capper cylinder
- To achieve fully retracted position, start the Capper cylinder with the valve guide:
- G31K1220 for S1 or G31K2220 for S2
- Repeat the items Reference to Reference until the gaps are zero between the Forming tube template and both of the Screw cap holder, with the Rod resting against the Capping station.
- Tighten the Lock nut while the Capper cylinder is activated with the valve guide in fully retracted position. Keep the Capper cylinder activated.

- Capping station
- Forming tube template
- Rod
- Screw cap holder
- Lock nut
- Screw
- Capper cylinder
- Push the Bridge against the forming tube until both Ejecting device stops mechanically against the Forming tube template.
- Make sure that the rod is still at mechanical stop against the front of the forming tube.
- With the Bridge in this position, tighten the Screw.
- Make sure that both of the Ejecting device are loose and not stuck against anything. Also make sure that the Bridge is loose.
- To release the capper cylinder from fully retracted position, remove the valve guide.

- Forming tube template
- Bridge
- Ejecting device
- Screw
- To achieve fully extended position, start and hold the valve for the Capper cylinder with the valve guide:
- G31K1219 for S1 or G31K2219 for S2
- Measure with a Feeler gauge to make sure that the distance C between the top of the Screw cap holder and the top of the Ejecting device is according to the illustration.
- If adjustment is needed, remove the valve guide to release the pressure in the Capper cylinder.
- Loosen the Lock nut. Then adjust the Adjustment screw with a 6-mm hex key.
- Repeat the items Reference to Reference until the distance C according to illustration is achieved.

C = 1 ±0.5 mm
- Screw cap holder
- Capper cylinder
- Ejecting device
- Feeler gauge
- Lock nut
- Adjustment screw
- Surface
- When the distance C is correct, tighten the Lock nut while the Capper cylinder is not activated with the valve guide.Note: The distance C is correct when the Surface of the Ejecting device are even with the top of the Screw cap holder.
- To achieve fully extended position, start and hold the valve for the Capper cylinder with the valve guide:
- G31K1219 for S1 or G31K2219 for S2
- Make sure that both of the Ejecting device are loose and not stuck against anything. Also make sure that the Bridge is loose.

C = 1 ±0.5 mm
- Screw cap holder
- Capper cylinder
- Bridge
- Ejecting device
- Feeler gauge
- Lock nut
- Adjustment screw
- Surface
- Use a Wrench to hold the capper unit.
- Remove the Setting template.
- Use the Wrench to lower the capper unit.

- Wrench
- Setting template
- Adjust the Bridge to achieve the distance C between the top of the Screw cap holder and the top of the Ejecting device. Measure the distance with a Feeler gauge.Note: The distance C is correct when the Surface of the Ejecting device are even with the top of the Screw cap holder.
- Tighten the Screw with the Bridge in this position.
- Make sure that both of the Ejecting device are loose and not stuck against anything. Also make sure that the Bridge is loose.
- To release the pressure in the capper cylinder, remove the valve guide.
- To achieve fully retracted position, start the Capper cylinder with the valve guide:
- G31K1220 for S1 or G31K2220 for S2
- Make sure that both of the Ejecting device are loose and not stuck against anything. Also make sure that the Bridge is loose.

C = 1 ±0.5 mm
- Screw cap holder
- Capper cylinder
- Bridge
- Ejecting device
- Feeler gauge
- Surface
- Screw
Finish the Basic Set
- Remove the valve guide.
- Assemble the spring and the servo motor that was removed during Preparations.
- If not following the Setting Sequence CAU, perform the following settings:
Capper Unit - Set Timing Belt
| Equipment Status | Program Step |
- Loosen the Nut.
- Increase the tension in the Timing belt by pressing the Nut according to the arrow in the illustration.
- Hold the Nut in position and tighten.

- Nut
- Timing belt
Capper Unit - Change Ball Bearings
| Equipment Status | Program Step |
- Remove the Nut, the Washer and the Screw to remove the Ball bearing.
- Change the Ball bearing and assemble in reverse order.
- Set the Timing belt according to:

- Nut
- Washer
- Screw
- Ball bearing
- Timing belt
Capper Unit - Change Servomotor
| Equipment Status | Program Step |
- Loosen the Nut to release the tension in the Timing belt.
- Remove the Screw and the Nut to remove the Holder and Holder.
- Remove the Electrical connection.
- Remove the Screw and the Washer to remove the Servomotor.

- Nut
- Timing belt
- Screw
- Nut
- Holder
- Holder
- Electrical connection
- Screw
- Washer
- Servomotor
- Loosen the Screw, with an Allen-key 2,5 mm, when it is visible through the Hole.
- Remove the Wheel.
- Remove the Screw to remove the Spacer.
- Change the Servomotor and assemble in reverse order.
- Assemble the wheel according to:
- Set the timing belt according to:

- Servomotor
- Screw
- Hole
- Wheel
- Screw
- Spacer
Capper Unit - Change Wheel
| Equipment Status | Program Step |
- Loosen the Nut to release the tension in the Timing belt.
- Rotate the Wheel until the Screw is visible through the Hole.
- Loosen the Screw with an Allen key.
- Remove the Wheel and change it.

- Nut
- Timing belt
- Wheel
- Screw
- Hole
- Assemble in the reverse order, and make sure that the surface of the Wheel is even with the end of the Shaft.
- Set the timing belt according to:

- Wheel
- Shaft
Capper Unit - Change Cylinder
| Equipment Status | Program Step |
- Disconnect the Pneumatic connection.
- Disconnect the Electrical connection for the Sensor.
- Remove the Screw, and the Washer.

- Pneumatic connection
- Electrical connection
- Sensor
- Screw
- Washer
- Capper unit
- Remove the Screw, and the Washer to remove the Cylinder.
- Use an Allen key to move the Sensor, from the old cylinder to the new cylinder and set them accordingly.
- Set the end positions for the new cylinder according to the old cylinder.
- Assemble in the reverse order.
- Set the new cylinder according to:
- Set the Sensor according to:

- Sensor
- Screw
- Washer
- Cylinder
Capper Unit - Change Sensor
| Equipment Status | Program Step |
- Remove the Electrical connection, for the Sensor.
- Loosen the Screw, with an Allen-Key.
- To remove the Sensor and change it.
- Assemble in reverse order.
- Set the new Sensor according to:
- The Sensor is changed in the same way.

- Electrical connection
- Sensor
- Screw
- Sensor
Capper Unit - Change Ball Bearing
| Equipment Status | Program Step HEATING |
| Consumables | Retaining compound: TP No. 344441-0000 |
- Loosen the Nut to release the tension in the timing belt.
- Remove the Screw and the Disc spring to remove the Ejecting device.
- Remove the Screw to remove the screw Cap holder.
- Remove the Screw to remove the End section.
- Remove the Retaining ring to remove the Belt unit.
- Remove the Ball bearing from the Belt unit and change it.
- Assemble in the reverse order.Note: The Disc spring must be assembled according to illustration to work as a spring.
- Apply retaining compound to the Screw before assembling and tighten it to 5.0Nm.

- Ejecting device
- Screw
- Cap holder
- Screw
- End section
- Retaining ring
- Ball bearing
- Belt unit
- Bushing
- Disc spring
- Screw
- Nut
Capper Unit - Set Screw Cap Colours
| Equipment Status | Program Step |
| Special Equipment | Keyboard |
Note: The Setting and information window also opens when you exit the Settings and information package counters window.- Connect a keyboard to the TPOP.
- To open the
Technical menu, press the F4 button on the keyboard. - To open the CAU window, for the side that you want to set the screw cap colour for, press the Icon.
- Select the screw cap colours that to be used in the machine by pressing them. An enclosing blue square indicates the selected colours.
- Exit the windows.

- Icon
Capper Unit - Change Cap Holder
| Equipment Status | Program Step step zero |
| Special Equipment | Setting Template TP No. 2901501-0000 |
- Lift and hold the capper unit using a Wrench.
- Put the Setting template in position.

- Setting template
- Wrench
- Remove the Screw.
- Remove and discard the Cap holder.
- Fit the new Cap holder and the Screw.

- Screw
- Cap holder
- Hold the capper unit using a Wrench.
- Remove the Setting template.
- Lower the capper unit using a Wrench.

- Setting template
- Wrench
Capper Unit - Basic Set
| Equipment Status | Program Step AIR ON |
| Special Equipment | Position Template (Base/Midi/Mini): TP No. 2844893-0200 Position Template (Screw Cap O38): TP No. 2989790 Position Template (Screw Cap C38): TP No. 3342748 Setting Template TP No. 2901501-0000 Valve Guide TP No. 3520946-0000 (Valid for Mecman) |
Preparations
- Open the Capping station.
- Remove the Screw and the Washer to remove the Servomotor.
- Loosen the Screw and remove the Spring.

- Capping station
- Screw
- Washer
- Servomotor
- Screw
- Spring
Risk of crushing.Be careful when activating the cylinder.The air cylinder will move if it is activated by compressed air.
- Loosen the Screw.
- Activate the Capper cylinder with the valve guide to achieve fully retracted position.
- G31K1220 for S1 or G31K2220 for S2 (2000)
- Y911 for S1 or Y931 for S2 (1900)
- Make sure that distance A measures according to the illustration.
- If adjustment is needed, remove the valve guide to release the pressure in the Capper cylinder.
- Loosen the Lock nut and adjust the Adjustment screw with a 4mm hex key.Repeat the items Reference to Reference until the distance A is achieved.
- When the distance A is correct, tighten the Lock nut while the capper cylinder is activated with the valve guide in fully retracted position. Keep the capper cylinder activated.

A (mm) = 4
- Screw
- Capper cylinder
- Lock nut
- Adjustment screw
- Loosen the Screw.
- Push the Capper unit downward to mechanical stop.
- Tighten the Screw with the Capper unit in this position.
- Loosen the Screw.

- Screw
- Capper unit
- Screw
Set Capper Unit Parallelism
- Use a Wrench to lift and hold the Capper unit.
- Put the Setting template in position.
- Position the Forming tube template.
- Put the Rod in position.
- Adjust the height with the Screw until the Forming tube template and the Screw cap holder are centred.
- Slide the Forming tube template forward until they enter the Screw cap holder.Note: If it is impossible to fit the forming tube templates in the screw cap holders, loosen the Screw keeping the screw cap holder in lowest possible position. Fit the forming tube templates in the screw cap holders, adjust the height with the Screw, if necessary, and then tighten the Screw.

- Wrench
- Capper unit
- Setting template
- Forming tube template
- Rod
- Screw cap holder
- Screw
- Screw
- Push and hold the entire Capper unit as close as possible to the Capping station.
- Make sure that gaps A are zero between the Forming tube template and both of the Screw cap holder.
- With the Capper unit held in this position, tighten the Screw.

- Forming tube template
- Screw cap holder
- Capper unit
- Capping station
- Screw
- Loosen the Screw.
- Measure distance B between the Bracket and the Beam.
- Adjust the height of the Setting template with the Screw until the distance B is reduced with 1 mm compared to the measurement under item k).
- Make sure that the Forming tube template are aligned against and rest against the capping station.
- Tighten the Screw with the capper unit in this position.Note: These steps are performed to make sure that the Screw end up in the middle of their setting holes.

- Setting template
- Forming tube template
- Screw cap holder
- Screw
- Screw
- Bracket
- Beam
Set Bridge and Cylinder End Positions
Risk of crushing.Be careful when activating the cylinder.The air cylinder will move if it is activated by compressed air.
Risk of damage to equipmentNever set the gap
A, illustrated under
Preparations, to less than 3mm. If the gap is smaller, there is a risk of damage to the equipment.
- Close a Capping station.
- Slide the Forming tube template forward until the Rod stops mechanically against the Capping station.
- Make sure that there is no gap between the Forming tube template and both of the Screw cap holder, with the Rod resting against the Capping station.
- If adjustment is needed, remove the valve guide to release the pressure in the Capper cylinder
- Loosen the Lock nut and adjust the adjustment Screw with a 4mm hex key.

- Capping station
- Forming tube template
- Rod
- Screw cap holder
- Lock nut
- Screw
- Capper cylinder
- Activate the Capper cylinder with the valve guide to achieve fully retracted position.
- G31K1220 for S1 or G31K2220 for S2 (2000)
- Y911 for S1 or Y931 for S2 (1900)
- Repeat the items b) to f) until the gaps are zero between the Forming tube template and both of the Screw cap holder, with the Rod resting against the Capping station.
- When this is achieved, tighten the Lock nut while the Capper cylinder is activated with the valve guide in fully retracted position. Keep the Capper cylinder activated.

- Capping station
- Forming tube template
- Rod
- Screw cap holder
- Lock nut
- Screw
- Capper cylinder
- Push the Bridge against the forming tube until both Ejecting device stops mechanically against the Forming tube template.
- Make sure that the rod is still at mechanical stop against the front of the forming tube.
- With the Bridge in this position, tighten the Screw.
- Make sure that both of the Ejecting device are loose and not stuck against anything. Also make sure that the Bridge is loose.
- Remove the valve guide to release the capper cylinder from fully retracted position.

- Forming tube template
- Bridge
- Ejecting device
- Screw
- Activate and hold the valve for the Capper cylinder with the valve guide to achieve fully extended position.
- G31K1220 for S1 or G31K2220 for S2 (2000)
- Y911 for S1 or Y931 for S2 (1900)
- Measure with a Feeler gauge to make sure that the distance C between the top of the Screw cap holder and the top of the Ejecting device is according to the illustration.
- If adjustment is needed, remove the valve guide to release the pressure in the Capper cylinder.
- Loosen the Lock nut and adjust the Adjustment screw with a 4mm hex key.
- Repeat the items n) to q) until the distance C according to illustration is achieved.

C (mm) = 1 ±0.5
- Screw cap holder
- Capper cylinder
- Ejecting device
- Feeler gauge
- Lock nut
- Adjustment screw
- Surface
- When distance C is correct, tighten the Lock nut while the Capper cylinder is not activated with the valve guide.Note: Distance C is correct when the Surface of the Ejecting device are even with the top of the Screw cap holder.
- Activate and hold the valve for the Capper cylinder with the valve guide to achieve fully extended position.
- G31K1220 for S1 or G31K2220 for S2 (2000)
- Y911 for S1 or Y931 for S2 (1900)
- Make sure that both of the Ejecting device are loose and not stuck against anything. Also make sure that the Bridge is loose.

C (mm) = 1 ±0.5
- Screw cap holder
- Capper cylinder
- Bridge
- Ejecting device
- Feeler gauge
- Lock nut
- Adjustment screw
- Surface
- Use a Wrench to hold the capper unit.
- Remove the Setting template.
- Use the Wrench to lower the capper unit.

- Wrench
- Setting template
- Adjust the Bridge to achieve distance C between the top of the Screw cap holder and the top of the Ejecting device. Measure the distance with a Feeler gauge.Note: Distance C is correct when the Surface of the Ejecting device are even with the top of the Screw cap holder.
- Tighten the Screw with the Bridge in this position.
- Make sure that both of the Ejecting device are loose and not stuck against anything. Also make sure that the Bridge is loose.
- Remove the valve guide to release the pressure in the Capper cylinder.
- Activate the Capper cylinder with the valve guide to achieve fully retracted position.
- G31K1220 for S1 or G31K2220 for S2 (2000)
- Y911 for S1 or Y931 for S2 (1900)
- Make sure that both of the Ejecting device are loose and not stuck against anything. Also make sure that the Bridge is loose.

C (mm) = 1 ±0.5
- Screw cap holder
- Capper cylinder
- Bridge
- Ejecting device
- Feeler gauge
- Surface
- Screw
Finish the basic set
- Remove the valve guide.
- Assemble the spring and the servomotor that was removed during Preparations.
- If not following the 4.1.5 Setting Sequence CAU, perform the following settings in the MM:
- 4.4.5-4 Capping Station - Set Spring
- 4.6.1-7 Capper Unit - Set Sensor
- 4.5.1-2 Screw Cap Transfer - Set Parallelism
- 4.5.1-3 Screw Cap Transfer - Set Overloading
- 4.5.1-4 Screw Cap Transfer - Set Sensor
- 4.6.2-3 Screw Cap Lift - Set End Positions
Capper Unit - Set Sensor
| Equipment Status | Program Step |
The yellow LED light on the Sensor (retracted position) and the Sensor (extended position) must light up to indicate that the capping cylinder is in an end position. The LED light on the Sensor (retracted position) for fully retracted cylinder and the LED light on the Sensor (extended position) for fully extended cylinder. A yellow and red LED light at the same time from a sensor indicates that the sensor is outside of the sensitivity interval.
- Capping cylinder
- Sensor (retracted position)
- Screw
- Sensor (extended position)
- Screw
Table below shows denominations for sensor cables according to SPC: | Machine Side 1 | Machine Side 2 |
| Cable for sensor (2) | G31W1219 (2000)W9108 (1900) | G31W2220 (2000)W9329 (1900) |
| Cable for sensor (4) | G31W1220 (2000)W9106 (1900) | G31W2219 (2000)W9328 (1900) |
- Make sure that the end positions for the capping cylinder is set according to:
- 4.6.1-17 Capper Unit - Basic Set.
- Remove the box and remove the servomotor according to:
- 4.7.1-1 Box - Remove in the MM.
- 4.6.1-9 Capper Unit - Change Servomotor in the MM.
- Hold the Capping cylinder in fully retracted position.
- Loosen the Screw on the Sensor (retracted position).
- Slide the Sensor (retracted position) to find the interval where the yellow LED light on the sensor lights up. A yellow and red LED light at the same time indicates that the Sensor (retracted position) is outside of the sensitivity interval.
- Set the Sensor (retracted position) in the middle of this interval and tighten the Screw.
- Release the Capping cylinder from fully retracted position.

- Capping cylinder
- Sensor (retracted position)
- Screw
- Sensor (extended position)
- Screw
- Hold the Capping cylinder in fully extended position.
- Loosen the Screw on the Sensor (extended position).
- Slide the Sensor (extended position) to find the interval where the yellow LED light on the sensor lights up. A yellow and red LED light at the same time indicates that the Sensor (extended position) is outside of the sensitivity interval.
- Set the Sensor (extended position) in the middle of this interval and tighten the Screw.
- Release the Capping cylinder from fully extended position.
- Assemble the servomotor and the box.

- Capping cylinder
- Sensor (retracted position)
- Screw
- Sensor (extended position)
- Screw
Capper Unit - Change Sensor
| Equipment Status | Program Step |
- Remove the Electrical connection, for the Sensor.
- Loosen the Screw, with an Allen-Key.
- Remove the Sensor.
- Install the new sensor.
- Assemble in reverse order.
- Set the new Sensor according to:
- 4.6.1-18 Capper Unit - Set Sensor.
- Repeat items a) to f) for the Sensor.

- Electrical connection
- Sensor
- Screw
- Sensor
Screw Cap Lift - Set Pneumatic Valve
| Equipment Status | Program Step |
- Loosen the Locknut
If the cylinder speed is to high it can damage the machineBe careful not to set the cylinder speed to high. Just set it high enough to avoid alarms.
Set the speed of the Cylinder with the Valve (extending movement) and Valve (retracting movement) using the Adjustment screw.- Tighten the Locknut to lock the valves.

- Cylinder
- Valve (extending movement)
- Valve (retracting movement)
- Adjustment screw
- Locknut
Screw Cap Lift - Set End Positions
| Equipment Status | Program Step step zero |
| Special Equipment | Position Template, TP No. 2844893-0200 Position Template, TP No. 2989790-0000 (Screw Cap O38) Position Template, TP No. 3342748-0000 (Screw Cap C38) Position Template, TP No. 3738867-0000 (Screw Cap C38 V2) Setting Template, TP No. 2901501-0000 Setting Template, TP No. 3061051-0000 (Screw Cap O38) Setting Template, TP No. 3568597-0000 (Screw Cap C38) Setting Template, TP No. 3729169-0000 (Screw Cap C38 V2) |
Set Cap Transfer Position
- Before performing this setting, make sure that the parallelism of the capper unit is set. See Procedure Capper Unit - Basic Set.
- Put a Feeler gauge between the Beam and the Bracket to centre the Screw cap holder with the transfer unit.Note: The distance between the Beam and the Bracket must be somewhere around 4 mm.

- Feeler gauge
- Beam
- Bracket
- Screw cap holder
- Position the Setting template inside the Screw cap holder.
- Extend the Capping cylinder by hand until the Loading piston enter the Setting template.
- If necessary, adjust the height of the capper unit and check with the feeler gauge. See item Reference.

- Screw cap holder
- Capping cylinder
- Loading piston
- Setting template
- Connect a keyboard to the TPOP.
- Push the F4 button to open the
Technical Menu. - Press
CAU technical window. - Note the value in Lift Actual position. Press Enable Increase/Decrease.
- Enter the value from Lift Actual position in Lift Transfer position with Increase or Decrease.
- Press Exit and press
save. 
Lift Actual positionLift Transfer positionIncreaseDecreaseEnable Increase/DecreaseExit
- Slide the Setting template into the Tube.Note: If the Setting template do not fit in the Tube, loosen the Screw.
- Adjust the Tube.Note: Removing the Screw and loosening the Chute eases the adjustment of the Tube.
- Tighten the Screw.
- Remove the Setting template from the loading pistons.
- Remove the feeler gauge from under the bracket.
- Set overload. See Procedure Screw Cap Transfer - Set Overloading.

- Setting template
- Tube
- Screw
- Screw
- Chute
Set Capping Position
- Use a Wrench to lift and hold the capper unit.
- Put the Setting Template in position.
- The height is adjusted with the Screw.

- Wrench
- Setting Template
- Screw
- Open the Capping station.
- Position the Position template.
- Put the Screw cap holder in position on the Position template.
- If necessary, adjust the height of the Capper unit according to the previous page.

- Position template
- Capping station
- Screw cap holder
- Capper unit
- Push the F4 button to open the
Technical Menu. - Press
CAU technical window. - Note the value in Lift Actual position. Press Enable Increase/Decrease.
- Enter the value from Lift Actual position in Lift Capping position with Increase or Decrease.
- Press Exit and press
Save. - Remove the Position template. Then close the capping stations.
- Remove the Setting Template.

Lift Actual positionLift Capping positionIncreaseDecreaseEnable Increase/DecreaseExit
Screw Cap Lift - Lubricate Compact Module
| Equipment Status | Program Step HEATING |
| Special Equipment | Grease gun: TP No. 950926-0000 |
| Consumables | Grease: TP No. 344407-0000 |
Note: This procedure is only valid for machines with Cap applicator.- Remove the Plug.
- Rotate the Shaft with a Wrench until the lubrication points become visible trough the Hole.
Too much grease can damage the seals.Lubricate with eight strokes of grease. Remove surplus lubrication.
Use a Grease gun and lubricate with eight strokes of grease in each lubrication point.- Release the Shaft and assemble the Plug in the Hole.

- Wrench
- Shaft
- Grease gun
- Hole
- Plug
Screw Cap Lift - Change Motor
| Equipment Status | Program Step |
- Remove the Electrical connection.
- Rotate the Shaft with a Wrench until a screw is visible trough the Hole.
- Loosen the screw with an Allen key while the Wrench is held in position.
- Release the Shaft, carefully.
- Remove the Screw and the Motor.

- Wrench
- Shaft
- Hole
- Electrical connection
- Screw
- Motor
- Remove the Sleeve and clean it with alcohol.
- Clean the Shaft and the contact Surface with alcohol.
- Also clean the surfaces marked with grey in the illustration.

- Motor
- Planetary gear
- Sleeve
- Shaft
- Surface
- Put the Sleeve back in the Planetary gear.
- Make sure that the Slit is positioned at the angel A from the Screw.
- Fit an Allen key in the Screw to prevent the Planetary gear from rotating.

A = 90º
- Hole
- Planetary gear
- Sleeve
- Slit
- Screw
- Allen key
- Assemble the Motor to the Planetary gear.Note: Assembly the Planetary gear so that the Hole is positioned according to the illustration.
- Fit the plastic cover in the Hole.
- Tighten the Screw.
- After tightening the Screw. Tighten the Screw to a torque of 9.5Nm.
- Assemble the Electrical connection.

- Hole
- Electrical connection
- Screw
- Motor
- Planetary gear
- Screw
Screw Cap Lift - Change Planetary Gear
| Equipment Status | Program Step HEATING |
- Remove the Electrical connection.
- Rotate the Shaft with a Wrench, until a screw is visible through the Hole. Loosen the screw.
- Remove the Screw, and remove the Planetary gear including the Motor.
- Remove the Planetary gear and assemble the new planetary gear to the Motor according to:

- Electrical connection
- Shaft
- Wrench
- Hole
- Screw
- Planetary gear
- Motor
- Remove the Sleeve, and clean with alcohol.
- Clean the Shaft and the Contact surface with alcohol.
- Also clean the surfaces marked with grey. See the illustration.

- Planetary gear
- Compact module
- Sleeve
- Shaft
- Contact surface
- Put the Sleeve back in the coupling.
- Make sure that the Slit is positioned at the angel A from the Screw.
- Fit an Allen key in the Screw to prevent the coupling from rotating.

A = 90°
- Hole
- Sleeve
- Slit
- Screw
- Allen key
- Assemble the Planetary gear with the Motor to the compact module.Note: Assembly the planetary gear so that the Hole is positioned according to the illustration.
- Fit the five plastic covers in the Hole and Hole.
- Tighten the Screw.
- After tightening the Screw. Tighten the Screw to a torque of 9,5 Nm.
- Assemble the Electrical connection.

- Electrical connection
- Shaft
- Wrench
- Hole
- Screw
- Planetary gear
- Motor
- Screw
- Hole
Screw Cap Lift - Change Compact Module
| Equipment Status | Program Step |
- Remove the Electrical connection.
- Support the Screw cap holder.
- Remove the Screw, and the Washer.
- Remove the Screw, and the Bracket, to remove the Compact module from the Frame.

- Electrical connection
- Screw cap holder
- Screw
- Washer
- Screw
- Bracket
- Compact module
- Frame
- Move the planetary gear and the motor to the new compact module. Use instructions given in:
- Assemble in reverse order.
Controlled Capping - Enable / Disable
| Equipment Status | Program Step heating |
There are two ways to enable or disable Controlled Capping.Alternative 1
- Connect a keyboard to the TPOP.
- Push F4 on the keyboard to open the
Technical Menu. - Press Main.

- Main
- Press Controlled Capping S1 or Controlled Capping S2, depending on production side.
- Press Enable Increase/Decrease.
- Enable or disable Controlled Capping by pressing Increase or Decrease.
- Press Exit and press
Save. 
- Controlled Capping S1
- Controlled Capping S2
- Increase
- Decrease
- Enable Increase/Decrease
- Exit
Alternative 2
Note: To enable/disable Controlled Capping this way, access must have been given to the operator. See Procedure .- Press Manoeuvre window and then the CAU button.
- Press Controlled Capping and On/Off, to enable/disable Controlled Capping.Note: When Controlled Capping is disabled, there is a green indicator on the Controlled Capping button.
- Press Exit.

- Manoeuvre window
- CAU
- On
- Off
- Controlled Capping
- Exit

Enabled

Disabled
Controlled Capping - Set Start-Angle
| Equipment Status | Program Step PRODUCTION |
Note: The start-angle must be set on all recipe and volume combinations:- The first time that they are introduced in the equipment.
- The first time that they are used after a mechanical change in the CAU.
- When a recipe colour for the cap has been changed.
The procedure searches for the optimal start-angle for controlled capping by testing different start-angles.- Make sure that the stripper home position is set. See Procedure CAU Stripper - Set Capping Reference.
- Step the machine up to Production.
- Connect a keyboard to the TPOP.
- Push F4 on the keyboard to open the
Technical Menu. - Press CAU technical window.

None
- Set the current side (S1 or S2) for the angle search:Note: Activating the search on Capper Motor X:1 also activates the search for Capper Motor X:2.

Capper Motor 1:1Capper Motor 2:1
- The number in the field for the Recommended Start-Angle indicates the search status, see the table.
| Status | Description |
| 666 | No search has been performed. |
| 999 | The search failed. |
| 0-115 | Showing the recommended start-angle. |

Recommended Start-Angle
- Do the search:
- If the search failed:

- Recommended Start-Angle
CalculateOnIndicator
- If the search succeeded:
- If manual change of the start-angle is needed:
- Press Exit and then press
Save. 
- Recommended Start-Angle
- Calculate
Start-AngleEnable Increase/DecreaseIncreaseDecreaseExit
Controlled Capping - Access for Operator
| Equipment Status | Program Step heating |
This procedure gives operators access to enable or disable Controlled Capping, perform a start angle Screening, and change the start angle.- Connect a keyboard to the TPOP.
- Push F4 on the keyboard to open the
Technical Menu. - Press Main.

- Main
- Press Controlled Capping, allow operator to adjust.
- Press Enable Increase/Decrease.
- To activate operator properties, press Decrease or Increase.
- Press Exit and press
Save. 
- Controlled Capping, allow operator to adjust
- Exit
- Enable Increase/Decrease
- Decrease
- Increase
Controlled Capping - Waste Failed Orientations
| Equipment Status | Program Step PRODUCTION |
If the machine produces a large number of packages with failed cap orientation, Waste Failed Orientations can be activated to separate the failed orientations from the rest. Waste Failed Orientations can be activated during production or Motor Running.- Connect a keyboard to the TPOP.
- Push F4 on the keyboard to open the
Technical Menu. - Press CAU technical window.

- CAU technical window
- Press Capper Motor 1:1 or Capper Motor 2:1, depending on production side.Note: Activating Waste Failed Orientations for Capper Motor X:1 starts Waste Failed Orientations for Capper Motor X:2.

Capper Motor 1:1Capper Motor 2:1
- Press Waste Failed Orientations and press ON to activate Waste Failed Orientations.Note: The Indicator on the Waste Failed Orientations button indicates that Waste Failed Orientations is running.Note: Waste Failed Orientations is automatically deactivated after one hour, or when the machine is stepped down below Motor Running.

- Waste Failed Orientations
- ON
- Indicator
Box - Remove
| Equipment Status | Program Step |
- Open the Door.
- Fold up the Chute.

- Door
- Chute
- Remove the Screw.
- Slide out the Box to remove it.
- To assemble the Box, perform the steps above in reverse order.

- Screw
- Box
Duct - Set Knife
| Equipment Status | Program Step step zero |
| Special Equipment | Position Template TP No. 3017556-0000 Position Template TP No. 3721168-0000 (Screw Cap C38 V2) |
- Loosen the Screw.
- Fit the Position Template, on the Mandrel.

- Screw
- Position Template
- Mandrel
Risk of crushingBe careful when rotating the
Mandrel. Moving
Mandrel can crush.
Risk of damage to equipmentRotate the
Mandrel by hand. Do NOT inch from the button on the
TPOP.The
Inner tool and the
Knife can be damaged if they strike each other.
The Mandrel must be rotated when aligning the position template. Rotate the Mandrel by hand in to position according to the illustration. The angel A must be 61 ±1° which can also be confirmed on the TPOP.
A = 61 ±1°
- Mandrel
- Inner tool
- Adjust the Knife according to the Position Template. Tighten the Screw.
Risk of damage to equipmentTo avoid damaging the duct, remove the
Position Template.The duct can be damaged.
Remove the Position Template.- Make sure that there is no risk of collision between the Mandrel and the Knife.
- Repeat for both the mandrels on S1 and for both mandrels on S2.

- Screw
- Position Template
- Mandrel
- Knife
Duct - Set Photocell
| Equipment Status | Program Step |
- Set the photocell to L (light mode), with the Screw.
- Set the Screw to MAX.
- Make sure that the photocell is clean.
- Check that the Green LED, on the photocells lights.
- Interrupt the beam and make sure that both Green LED and Orange LED lights up.

- Screw
- Screw
- Green LED
- Orange LED
Frame - Check Photocell
| Equipment Status | Program Step |
- Empty the CSU from screw caps according to the OM.
- Make sure that the Photocell is clean.
- Make sure that the reflector on the CSU lid is clean.
- Check that the Green LED, on the Photocell lights.
- Interrupt the beam and make sure that both the Green LED and the Orange LED light up. If not, set the photocell according to:

- Photocell
- Green LED
- Orange LED
Frame - Set Inductive Switch
| Equipment Status | Program Step |
The CSU has inductive switches in 4 positions pointed out by arrows in the illustration below. These inductive switches are there to make sure that the doors and the lids are closed when the machine is running. Perform the following steps to set one or more of these inductive switches.- Adjust the Inductive switch with the Nut.
- Adjust until the Surface of the Inductive switch is 1-2 mm away from the inside of the Door or the inside of the Lid, depending on which Inductive switch is adjusted.
- All four Inductive switch are adjusted in the same way.

- Inductive switch
- Nut
- Surface
- Door
- Lid
Frame - Set Photocell
| Equipment Status | Program Step |
- Empty the CSU from screw caps according to the OM.
- Make sure that the Photocell reads through the Hole.
- If adjustment is needed, loosen the Nut, adjust, and tighten the Nut.
- Turn the Screw towards MAX until both the Green LED and the Orange LED light up.
- Turn the Screw towards MIN until only the Green LED lights.

- Photocell
- Hole
- Nut
- Screw
- Green LED
- Orange LED
Frame - Clean pipes
| Equipment Status | Program Step Program Step |
| Special Equipment | Foam pig TP No. 90600-6003 (3 inch) Foam pig TP No. 90600-6004 (4 inch) |
| Consumables | Alcoholic Solution (Ethanol 70%) |
- Remove all Clamp from the Ferrule in the pipe system.
- Remove all Gasket from the Ferrule.
- If necessary remove the pipes from the installation attachments.
- Put a Pulling wire through one pipe at the time and attach the correct Foam pig, for 3 inch pipe or for 4 inch pipe.
- Soak the Foam pig in alcoholic solution (Ethanol 70%), see Chemicals for Cleaning and Disinfection.

- Clamp
- Ferrule
- Gasket
- Pulling wire
- Foam pig
- Clean one pipe at a time. The cleaning is completed when the pipes are visually clean.
- Clean the Gasket with alcoholic solution (Ethanol 70%).
- Assemble the pipe system with Gasket and Clamp. Change gaskets if they are damaged.Note: The pipe system must be disconnected at all joints to keep soil from building up in the joints during cleaning.Note: The illustration shows one example of the pipe installation. The installation looks different for every individual machine.

- Clamp
- Ferrule
- Gasket
- Pulling wire
- Foam pig
Frame - Change Pre-Filter
| Equipment Status | Program Step |
- Change the Filter.

- Filter
Frame - Change Cap Container Filter
| Equipment Status | Program Step |
- Remove the Nut to remove the Cover, and the Filter.
- Install a new Filter in the Cover.
- Guide the Filter with your fingers when installing the new Filter and the Cover on the Filter bracket.
- Tighten the Nut.

- Nut
- Cover
- Filter
- Filter bracket
Frame - Change Filter
| Equipment Status | Program Step |
- Remove the Nut to remove the Cover. Remove the Filter.
- Change the filter, and assemble in the reverse order.

- Nut
- Cover
- Filter
Frame - Change Inductive Switch
| Equipment Status | Program Step |
The CSU has inductive switches in 4 positions pointed out by arrows in the illustration below. Perform the following steps to change one or several of these inductive switches.- Disconnect the Electrical connection.
- Remove the Nut to remove the Inductive switch.
- Change the Inductive switch and assemble in the reverse order.
- Set the new inductive switch according to:

- Electrical connection
- Nut
- Inductive switch
Frame - Change Photocell
| Equipment Status | Program Step |
- Disconnect the Electrical connection.
- Remove the Nut, the Washer, the Screw, the Bracket and the Photocell.
- Change the photocell and assemble in the reverse order.
- Set the photocell according to:

- Electrical connection
- Nut
- Washer
- Screw
- Bracket
- Photocell
Frame - Change Vibrator
| Equipment Status | Program Step |
- Remove the electrical connections from the Vibrator.
- Remove the Nut.
- Remove the Vibrator and change it.
- Assemble in the reverse order

- Vibrator
- Nut
Feed Unit - Set Fan Speed
| Equipment Status | Program Step |
| Special Equipment | Wind meter can be borrowed from CB Technical Support |
Note: The air speed must not exceed 10m/s. Lower airspeed is acceptable as long as the function of the CSU is satisfactory.- Empty the CSU from screw caps according to the OM.
- Activate the parameter A410 (PF525) on the frequency converter.
- Remove the Lid.
- Measure the airspeed in the Pipe opening with a wind meter and change the setting value for the parameter A410 (PF525). When an airspeed of 10m/s is achieved, note the setting value.
- Change the setting value for the parameter A410 (PF525) back to 15, according to the table applicable for your setup:
- Change the setting value for the parameter A411 (PF525) to the noted value.
- Save the parameter A411 (PF525) and the setting is finished.

- Lid
- Cyclone
- Pipe opening
Feed Unit - Change Fan
| Equipment Status | Program Step |
- Loosen the Hose clip and disconnect the Hose from the Pipe.

- Hose clip
- Hose
- Pipe
Risk of crushingThe CSU lid must be secured in open position.The CSU lid can fall down and crush your fingers.
- Open the Lid.
- Secure the Lid in open position.

- Lid
- Disconnect the Gas spring and the Washer from both sides of the Lid.
- Close the Lid.

- Lid
- Gas spring
- Washer
- Remove the Screw and the Bracket.
- Remove the Lid from the machine.

- Screw
- Bracket
- Remove the five Nut and washer, the Earth wire, and the Vibrator.
- Place the Vibrator on the floor of the CSU. Do not disconnect the cable.
- Save the Nut and washer and the Earth wire for later use.

- Nut and washer
- Earth wire
- Vibrator
- CSU
- Remove the Nut and the Photocell with bracket.
- Place the Photocell with bracket on the floor of the CSU.Note: This is done to protect the photocell from being damaged when removing the container.

- Nut
- Photocell with bracket
Heavy partsIt is recommended to use two persons when removing or installing the container.The container is heavy and can cause personal injury.
- Lift the Container.

- Container
- Remove the four Screw.
- Remove the four Screw.

- Screw
- Screw
- Disconnect the electrical connections for the Fan.
- Remove the Screw, the Washer, and the Nut.
- Lift out the Fan and change it.
- Assemble in the reverse order.Note: Make sure to move the container vertically downwards in order to not damage the sealing strips.

- Fan
- Screw
- Washer
- Nut
Feed Unit - Conveyer Belt
| Equipment Status | Program Step |
Check Belt Wear
- Check the belt for wear. Pay special attention to the edges of the belt.
- If the belt shows any sign of wear, replace it according to Change Conveyer Belt.
Check Belt Alignment
- Check belt alignment. If it is not centred, continue with items b) and c).
- Release the Screws to release the tension of the belt.
- Use a screwdriver or a similar object at the Adjustment points to adjust the Roller brackets.

- Screws
- Adjustment points
- Roller brackets
Change Conveyer Belt
- Empty the CSU from screw caps according to the OM.
- Disconnect the electrical connections for the Belt conveyer.
- Remove the cable from the Cable tie.
- Remove the Screw, Washer that hold the Bracket.
- Remove the Belt conveyer, including the Bracket.

- Belt conveyer
- Cable tie
- Screw, Washer
- Bracket
- Remove the Cover.
- Remove the Springs.
- Loosen the Screws.
- Move the Geared motor unit to release the tension on the Timing belt.
- Remove the Conveyor roller.
- Remove the Spacer.
- Remove the Guide and the Hatch.
- Remove the Conveyor Belt from the Bracket.
- Install the new conveyor belt.
- Assemble in the reverse order.

- Cover
- Springs
- Screws
- Geared motor unit
- Timing belt
- Conveyor roller
- Guide
- Hatch
- Conveyor Belt
- Bracket
Feed Unit - Timing Belt
| Equipment Status | Power must be turn OFF.
|
Check Timing Belt
- Remove the cover.
- Check the teeth on the timing belt for wear. If the teeth are worn, change the timing belt according to Change Timing Belt.
- Assemble the cover.
Change Timing Belt
- Remove the Cover.
- Remove the Springs.
- Loosen the Screws.
- Move the Geared motor unit to reduce the tension on the Timing belt.
- Remove the old Timing belt.
- Install in the reverse order.
- Move the Geared motor unit to increase the tension on the Timing belt.
- Tighten the Screws.

- Cover
- Springs
- Screws
- Geared motor unit
- Timing belt
Lid - Check Gas Spring
| Equipment Status | Program Step |
- Open the Lid.
- If the Lid can not stay in open position without support, the Spring must be changed. See procedure Lid - Change Gas Spring.

- Lid
- Spring
Lid - Change Gas Spring
| Equipment Status | Program Step |
Risk of crushingThe CSU lid must be secured in open position when changing the springs.The CSU lid can fall down and crush your fingers.
- Open the Lid.
- Secure the Lid in open position.

- Lid
- Remove the Gas spring and the Washer from both sides of the Lid.
- Install new Gas spring and close the Lid.

- Lid
- Gas spring
- Washer
Lid - Change Sealing Strip
| Equipment Status | Program Step |
- Open the Lid.
- Secure the Lid in open position.

- Lid
Risk of crushingThe CSU lid must be secured in open position when changing the springs.The CSU lid can fall down and crush your fingers.
- Remove the Gas spring and the Washer from both sides of the Lid.
- Close the Lid.

- Lid
- Gas spring
- Washer
- Remove the Screw and the Bracket .
- Remove the Lid from the machine.

- Lid
- Screw
- Bracket
- Turn the Lid upside down on a flat surface.
- Remove the Old strip and any residues.

- Lid
- Old strip
- Cut the sealing strip to a length of 1050 mm. Make sure it is cut in a 90° angle.Note: It is important not to stretch the sealing strips after the paper cover has been removed. This can reduce their sealing performance.
- Install the First sealing strip on the left side of the Lid according to measurements A and B.Note: All measurements are to be measured from the inside edge of the Lid.

A=21 ±1 mm
B = 56 ±1 mm
- Lid
- First sealing strip
- Cut the sealing strip to two lengths of 1015 mm to make the Second sealing strip and the Third sealing strip. Make sure that they are cut in a 90° angle.
- Install the Second sealing strip and the Third sealing strip tightly against the First sealing strip.
- Make sure that the Second sealing strip and the Third sealing strip are installed according to the measurements C and D below.Note: All measurements are to be measured from the inside edge of the lid.

C = 69 ±1 mm
D = 20 ±1 mm
- Lid
- First sealing strip
- Second sealing strip
- Third sealing strip
- Cut the sealing strip to a length of 1050 mm to make the Fourth sealing strip. Make sure it is cut in a 90-degrees angle.
- Install the Fourth sealing strip tightly against the Second sealing strip and the Third sealing strip.
- Make sure that the Fourth sealing strip is installed 21±1 mm from the edge of the lid.Note: all measurements are to be measured from the inside edge of the lid

E = 56 ±1 mm
- Second sealing strip
- Third sealing strip
- Fourth sealing strip
- Assemble the lid in the reverse order. See items Reference to Reference.
- Make sure that the new sealing strips are tight against the container and are sealing properly.Note: if the sealing strips are not seated properly against the container, the necessary overpressure inside the CSU is not obtained.
Connection Box
For information on how to change frequency converters and so on, see chapter Electrical System.Vision Unit
Laser RadiationWhen the
Protective cover are dismantled or when the vision unit is removed from the conveyor, the power supply disconnector must be switched off.The vision unit contains a
Laser unit that can cause damage to your eyes if you look into it.

- Laser unit
- Protective cover
- Laser beam
Description
There are three versions of the vision unit for the TetraTop® equipment.The following table differentiates between the three versions.| Version | Description | Cross-reference | Illustration |
| Vision Unit | Vision Unit 2959296-0200 with IVC Camera 90600-3655 | Vision Unit |  |
| Vision Unit | Vision Unit 2959296-0200 with TriSpector Camera 90609-9813 | Vision Unit |  |
| Vision Unit | Vision Unit 3764870-0100 with TriSpector Camera 90609-9813 | Vision Unit |  |
Vision Unit - Check Curtain
| Equipment Status | Program Step |
Laser radiationIf the vision unit is removed from the conveyor, the power supply disconnector must be switched off.The vision unit contains a laser unit that can cause damage to your eyes if you look into it.
- Check the curtain for any wear or damage.
- Change if necessary, see Procedure Vision Unit - Change Curtain on page Vision Unit - Change Curtain.
Vision Unit - Set Position
| Equipment Status | Power must be turn ON. Program Step |
| Special Equipment | Bar template TP No. 2959295-0000 |
Laser radiationIf the vision unit is removed from the conveyor, the power supply disconnector must be turned off.The vision unit contains a laser unit that can cause damage to your eyes if you look into it.
- Loosen the Nut.
- Remove the Bar from the Nut to remove the Support.
- Repeat the items a) to b) for both supports on the vision unit.

- Nut
- Bar
- Nut
- Support
- Loosen the Screw.
- Raise the height of the Camera unit to mechanical stop and tighten the Screw.

- Screw
- Camera unit
- Position the vision unit above the gap in the railing.
| Distance | A (mm) | B (mm) | C (mm) |
| 500±5 | 450±5 | 300±5 |

- Rail
- Rail holder
- Remove the Pipe.
- Position the Bar template in the holes.

- Pipe
- Bar template
- Loosen the Screw (4pcs) to lower the camera unit.
- The Bar template must rest against the Conveyor belt.

- Screw
- Bar template
- Conveyor belt
- Move the vision unit to center the Camera unit with the Conveyor. Verify by measuring the distances A and B between the Beam and the center of the Conveyor.

A (mm) = B (mm) = 100±5
- Camera unit
- Conveyor
- Beam
- Lift the Camera unit and tighten the Screw (4pcs) to achieve a gap between the Bar template and the conveyer belt (9).
- Adjust the Articulated foot to adjust the gaps C and D according to illustration.Note: The gaps C and D must be equal for both Bar template .Note: Use a Spirit Level to make sure that the Conveyer and the Camera Unit is in a horizontal position.
- Lock the Articulated foot in position and remove the Bar template.

C = D = 0.5+0.5/-0 mm
- Screw
- Camera unit
- Pipe
- Bar template
- Put the two Support in position.Note: Only one of the two supports are shown in the illustration.
- The Bar can be assembled in 3 different position depending on conveyer height.
- Tighten the Nut.
- Tighten the Clamp against the conveyer.
- Confirm the measurements of the distances A, B according to earlier page in this procedure.
- Assemble the pipes (7).

- Nut
- Bar
- Support
- Rail
- Clamp
- Loosen the Screw.
- Adjust the Guide to achieve the distance E.
- Adjust the bars (7) to the Guide.
- Tighten the Screw.

Base E (mm) = 90
Midi E (mm) = 70
Mini E (mm) = 60
- Rail
- Screw
- Guide
- If the vision unit seems instable, attach the vision unit to the floor with Bolt.
- Set fine adjustment according to

- Bolt
Vision Unit- Set fine adjustment with PC
| Equipment Status | Program Step |
| Special Equipment | Computer and ethernet cable |
Laser radiationIf the vision unit is removed from the conveyor, the power supply disconnector must be switched off.The vision unit contains a laser unit that can cause damage to your eyes if you look into it.
- Check and set the cutting angle according to Procedure Cutting Device - Check Knives on page Cutting Device - Check Knives.
- Set the camera angle according to:
- Connect a ethernet cable from the computer to the ethernet switch G31X0235 in the main electrical cabinet.
- Change the IP address according to:
- Open a web browser and go to the following address:
- http://10.255.1.24 /status.html (for camera on side 1)
- http://10.255.1.25/status.html (for camera on side 2)
- Let a package pass the vision unit on the conveyer.
- Press F5 to update the image in the browser.
- An image will appear showing a cross section of the package profile, if the image looks likeNote: For MiniV Nallo, also see .
- Example A, the setting of the camera is good.
- Example B, the height of the camera must be increased.
- Example C, the height of the camera must be decreased.
- Example D, the camera must be adjusted sideways.
- Example E, the camera must be tilted.
- Example F, there is direct sunlight in the area of measurement. The sunlight must be shielded.
- Adjustments are performed according to:
- 4.10-5 Vision Unit - Set Camera Angle
- Vision Unit - Set Position
| A. GOOD setting, the package is centered in the camera view. | | B. NOT good, the camera is positioned too low. | | C. NOT good, the camera is positioned too high. |
| | | | |
 | |  | |  |
| | | | |
| D. NOT good, the camera is positioned too far to the right. | | E. NOT good, the camera is tilted. | | F. NOT good, direct sunlight on the package or camera. |
| | | | |
 | |  | |  |
Vision Unit - Set Fine Adjustment via TPOP
Laser radiation.If the vision unit is removed from the conveyor, the power supply disconnector must be turned off.The vision unit contains a laser unit that can cause damage to your eyes if you look into it.
Note: For MiniV Nallo, also see .- Check and set the cutting angle according to Procedure Cutting Device - Check Knives on page Cutting Device - Check Knives.
- Press Show image.
- Let a package pass through the vision unit.
- Check the package from top view Package from top view. If the whole, or most part of the package is outside the Package from top view the conveyor speed is faulty.Make sure that the external conveyer speed is correct. It must be 15 m/min.

- Show image
- Package from top view
- Package from side view
- Check the package from side view Package from side view. If the Package from side view looks like:Note: For MiniV Nallo, also see .
- Example A, the setting of the camera is good.
- Example B, the height of the camera must be increased.
- Example C, the height of the camera must be decreased.
- Example D, the camera must be adjusted sideways.
- Example E, the camera must be tilted.
- Example F, there is direct sunlight in area of measurement. The sunlight must be shielded.
- Adjustments are performed according to:
- Vision Unit - Set Position.
- 4.10-5 Vision Unit - Set Camera Angle.
| A. PASS: setting, the package is centered in the camera view. | | B. FAIL, the camera is positioned too low. | | C. FAIL, the camera is positioned too high. |
| | | | |
 | |  | |  |
| | | | |
| D. FAIL, the camera is positioned too far to the right. | | E. FAIL, the camera is tilted. | | F. FAIL, direct sunlight on the package or camera. |
| | | | |
 | |  | |  |
Vision Unit - Set Camera Angle
| Equipment Status | Program Step |
Laser radiationIf the vision unit is removed from the conveyor, the power supply disconnector must be switched off.The vision unit contains a laser unit that can cause damage to your eyes if you look into it.
- Loosen the Screw on the Guide unit.
- Make sure that the Laser beam hits the correct area of the receiver lens (see pointer arrow).
- Tighten the Screw.

- Screw
- Guide unit
- Laser beam
Vision Unit - Change Curtain
| Equipment Status | Program Step |
Laser radiationIf the vision unit is removed from the conveyor, the power supply disconnector must be switched off.The vision unit contains a laser unit that can cause damage to your eyes if you look into it.
- Remove the Screw and the Plate.
- Change the Curtain.
- Assemble in the reverse order.

- Screw
- Plate
- Curtain
Vision Unit - Set Fine Adjustment for MiniV Nallo
Specific checks for MiniV Nallo, add MidiX checks for(Octa or Cape) when implementedLaser radiation.If the vision unit is removed from the conveyor, the power supply disconnector must be turned off.The vision unit contains a laser unit that can cause damage to your eyes if you look into it.
- Check and set the cutting angle according to Procedure Cutting Device - Check Knives on page Cutting Device - Check Knives.
- Press Show image.
- Let a package pass through the vision unit.
- Check the package from top view Package from top view. If the whole, or most part of the package is outside the Package from top view the conveyor speed is faulty.Make sure that the external conveyer speed is correct. It must be 15 m/min.

- Show image
- Package from top view
- Package from side view
Pass/Fail for MiniV Nallo- Check the Nallo package from side view Package from side view :

A: Fail: Position of camera is too high

B: Fail: Position of camera is too low

C: Pass: Position of camera is correct
- If the image is according to A or B, adjust the camera according to Adjust Camera Position.
Adjust Camera Position
- Loosen the Screws (8pcs) to free the Clamps .
- Check the position of the Cylinder, the distance A has the following dependency:
| Dependency | Distance |
| Cylinder is in upper position | A= 388 -1.0/+0 mm |
| Cylinder is in lower position | A= 338-1.0/+0 mm |
- Adjust the Articulated foot (3pcs) to achieve the distance A between the Camera Unit and the surface of the Articulated foot.Note: Turn the Articulated foot half a turn at the time to set the distance A.
- Use a spirit level to make sure that the Articulated foot and the Camera Unit are levelled relative to each other.Note: Use the spirit level on the Cylinder, to get a precise value of the Camera Unit.
- Lock the Articulated foot when the distance A is set.
- Fasten the Clamps with the Screws.

- Screws
- Clamps
- Cylinder
- Articulated foot
- Camera Unit
Vision Unit - Check Incorrect Read via TPOP
The information about Incorrect read from the vision camera can be used when evaluating the performance of the vision camera, and for troubleshooting function.- Connect a keyboard to the TPOP.
- Push F4 on the keyboard to open the Technical Menu.
- Push the Button to open the
CAU technical window. 
- Button
- Press the Go to sub menu button to go to the second page of the
CAU technical window.
- Compare the information about Incorrect read vision on S1 and S2 and Injection completed on S1 and S2 on S1 and S2.
- If the amount of Incorrect read vision on S1 and S2 is high compared to the amount of Injection completed on S1 and S2, adjust the vision camera. See Procedure Vision Unit - Set Position and 4.10-5 Vision Unit - Set Camera Angle. For MiniV Nallo, see Vision Unit - Set Fine Adjustment for MiniV Nallo.Note: Fallen packages are included in incorrect read. However, the proposed adjustments will not necessarily stop packages from falling and will therefore not automatically lower the amount of Incorrect read.
- Fallen package below the vision camera
- Wrong conveyor speed (15m/min recommended)
- No space between packages when they pass the camera
- Rotated packages on the conveyor
- Packages too close to the camera
- Packages too far from the camera
- Packages not centred in the camera view

- Injection completed on S1 and S2
- Incorrect read vision on S1 and S2
Reset of Incorrect Read Vision
- Press the Manoeuvre window, and then press the CAU S1 for S1 or S2 to open the Setting and information CAU.
- Press the Enable Increase/Decrease button to choose reset for Reset for S1 or Reset for S2.
- Press
Reset for the machine side that needs reset of the Incorrect read vision.Note: Pressing Reset resets all information, including Incorrect read vision. 
Manoeuvre window buttonCAU button S1Setting and information CAU buttonEnable Increase/Decrease button- Reset for S1
- Reset for S2
Position Cylinder - Set
| Equipment Status | Program Step |
Laser radiationIf the vision unit is removed from the conveyor, the power supply disconnector must be switched off.The vision unit contains a laser unit that can cause damage to your eyes if you look into it.
- Loosen the Contra nut.
- Close the check valves on the Position cylinder with the Adjustment screw and Adjustment screw.
- Open the check valve 8 turns with the Adjustment screw.
- Open the check valve 2 turns with the Adjustment screw.
- Tighten the Contra nut and the setting is finished.

- Contra nut
- Position cylinder
- Adjustment screw
- Adjustment screw
Camera Unit - Set Bottom Format
| Equipment Status | Program Step HEATING |
Laser radiationIf the vision unit is removed from the conveyor, the power supply disconnector must be switched off.The vision unit contains a laser unit that can cause damage to your eyes if you look into it.
- To set the bottom format for the vision system, the height of the camera unit must be adjusted.
- Assemble the screws in the Hole for Base for bottom format Base.
- Assemble the screws in the Hole for Midi/Mini for bottom format Midi.Assemble the screws in the Hole for Midi/Mini for bottom format Mini if the CAP Vision software version is 1006 or higher.
- Assemble the screws in the Hole for Mini for bottom format Mini if the CAP Vision software version is 1005 or lower.
Note: Information about the CAP Vision software version can be found on the TPOP. See Procedure .Note: Mini 330 ml must have CAP Vision software version 1006 or higher. 
- Hole for Base
- Hole for Midi/Mini
- Hole for Mini
Photocell - Check
| Equipment Status | Program Step |
Laser radiationIf the vision unit is removed from the conveyor, the power supply disconnector must be switched off.The vision unit contains a laser unit that can cause damage to your eyes if you look into it.
- Check that the Diode (Red) lights on the Photocell (transmitter).
- Check that the Diode (Red) and the Diode (Green) lights on the Photocell (receiver).
- Check that only the Diode (Red) is switched off when the Beam is interrupted.

- Photocell (transmitter)
- Diode (Red)
- Beam
- Diode (Red)
- Photocell (receiver)
- Diode (Green)
Photocell - Set
| Equipment Status | Program Step |
Laser radiationIf the vision unit is removed from the conveyor, the power supply disconnector must be switched off.The vision unit contains a laser unit that can cause damage to your eyes if you look into it.
- Remove the Photocell (transmitter) according to:
- Open the Hatch on the Photocell (transmitter).
- Set the Dip switch to PNP.
- Set the Dip switch to D (dark mode).
- Set the Screw for sensitivity to MAX.
- Close the Hatch.
- Assemble the photocell according to:
- Check the function according to:

- Hatch
- Photocell (transmitter)
- Dip switch
- Dip switch
- Screw
Cylinder - Change
| Equipment Status | Power must be turn ON. Program Step |
Laser radiation-If the vision unit is removed from the conveyor, the power supply disconnector must be turned off.The vision unit contains a laser unit that can cause damage to your eyes if you look into it.
- Remove the L-fitting from the Cylinder.
- Remove the Nut to remove the Cylinder from the Bracket.
- Loosen the Contra nut.
- Remove the Pusher.
- Change the Cylinder.
- Open the Regulator fully. The Regulator must be adjusted according to the bottom format that is used in each individual machine.
- Assemble in the reverse order

- L fitting
- Cylinder
- Nut
- Bracket
- Contra nut
- Pusher
- Regulator
Photocell - Change
| Equipment Status | Program Step |
Laser radiationIf the vision unit is removed from the conveyor, the power supply disconnector must be switched off.The vision unit contains a laser unit that can cause damage to your eyes if you look into it.
Note: Instruction shows how to change the Photocell (transmitter), the Photocell (receiver) is changed in the same way.- Disconnect the electrical connection for the Photocell (transmitter) in the connection box.
- Remove the Screw to remove the Photocell (transmitter).
- If the transmitter is changed, set the new photocell according to:
- Change the photocell and assemble in the revers order.

- Photocell (transmitter)
- Photocell (receiver)
- Screw
Vision Unit - Set Position
| Equipment Status | Power must be turn OFF. Air must be turn OFF.
|
| Special Equipment | Bar template TP No. 2959295-0000 |
Laser radiation hazard.The electrical supply disconnecting device must be in position O (OFF) and secured with a lock before any maintenance.The vision unit contains a laser unit that could cause eye injury.
- Loosen the Nut.
- To remove the Support, remove the Bar from the Nut.
- Repeat items Reference to Reference for both supports on the vision unit.

- Nut
- Nut
- Support
- Bar
- Loosen the Screw.
- Raise the height of the Camera unit to mechanical stop and tighten the Screw.

- Camera unit
- Screw
- Position the vision unit above the gap in the railing.

A = 500 ±5 mm
B = 450 ±5 mm
C = 300 ±5 mm
- Rail
- Rail holder
- Remove the Rail.
- Position the Bar template in the holes.

- Rail
- Bar template
- To lower the camera unit, loosen the four Screw.
- Make sure that the Bar template rest against the Conveyor belt.

- Screw
- Bar template
- Conveyor belt
- Move the vision unit to centre the Camera unit with the Conveyor. Verify by measuring distances D and E between the Beam and the centre of the Conveyor.

D = E = 100 ±5 mm
- Beam
- Camera unit
- Conveyor
- Lift the Camera unit and tighten the four Screw to achieve a gap between the Bar template and the Conveyor belt.
- Adjust the Articulated foot to adjust gaps F and G according to the illustration.Note: Gaps F and G must be equal for both Bar template.Note: Make sure that the conveyor and the camera unit are in a horizontal position by using a spirit level.
- Lock the Articulated foot in position and remove the Bar template.

F = G = 0.5+0.5/-0 mm
- Camera unit
- Screw
- Bar template
- Conveyor belt
- Put each Support in position.Note: Only one of the two supports is shown in the illustration.
- The Bar can be assembled in three different positions depending on the height of the conveyor.
- Tighten the Nut.
- Tighten the Clamp against the conveyor.
- Make sure that the distance between the Beam and the centre of the Conveyor are according to distances D and E.
- Assemble the Rail.

D = E = 100 ±5 mm
- Nut
- Support
- Bar
- Rail
- Beam
- Conveyor
- Clamp
- Loosen the Screw.
- To achieve distance H, adjust the Guide.
| Bottom format | Distance H |
| Base | 90 mm |
| Midi | 70 mm |
| Mini | 60 mm |
- Adjust the Rail to the Guide.
- Tighten the Screw.

- Rail
- Screw
- Guide
- If the vision unit seems unstable, attach the vision unit to the floor with Bolt.
- Set the fine adjustment according to Procedure Vision Unit - Set Fine Adjustment via TPOP.

- Bolt
Vision Unit - Set Fine Adjustment via TPOP
TT3 2000 | Equipment Status | Power must be turn ON.
|
Laser radiation hazard.The electrical supply disconnecting device must be in position O (OFF) and secured with a lock before any maintenance.The vision unit contains a laser unit that could cause eye injury.
- Check and set the cutting angle according to Procedure Cutting Device - Check Knives.
- Press Show image.
- Let a package pass through the vision unit.
- Check the package from top view Package from top view. If the whole, or most part of the package is outside the Package from top view, the conveyor speed is faulty.Make sure that the external conveyor speed is correct. It must be 15 m/min.

- Package from top view
- Package from side view
- Show image
- Check the package from side view Package from side view. If the Package from side view looks like:
- Example A, the setting of the camera is good.
- Example B, the height of the camera must be increased.
- Example C, the height of the camera must be decreased.
- Example D, the camera must be adjusted sideways.
- Example E, the camera must be tilted.
- Example F, there is direct sunlight in area of measurement. The sunlight must be shielded.
- Perform adjustments according to
Vision Unit - Check Incorrect Read via TPOP
TT3 2000 | Equipment Status | Power must be turn ON.
|
The information about Incorrect read from the vision camera can be used when evaluating the performance of the vision camera, and for troubleshooting function.- Connect a keyboard to the TPOP.
- Push F4 on the keyboard to open the Technical Menu.
- Push the Button to open the
CAU technical window. 
- Button
- Press the Go to sub menu button to go to the second page of the
CAU technical window.
- Compare the information about Incorrect read vision on S1 and S2 and Injection completed on S1 and S2 on S1 and S2.
- If the amount of Incorrect read vision on S1 and S2 is high compared to the amount of Injection completed on S1 and S2, adjust the vision camera. See Procedure Camera Unit - Set the Height of the Frame, Procedure Camera Unit - Set the Cover to Horizontal, and Procedure Camera Unit - Set the Camera.Note: Fallen packages are included in incorrect read. However, the proposed adjustments will not necessarily stop packages from falling and will therefore not automatically lower the amount of Incorrect read.
- Fallen package below the vision camera
- Wrong conveyor speed (15m/min recommended)
- No space between packages when they pass the camera
- Rotated packages on the conveyor
- Packages too close to the camera
- Packages too far from the camera
- Packages not centred in the camera view

- Injection completed on S1 and S2
- Incorrect read vision on S1 and S2
Reset of Incorrect Read Vision
- Press the Manoeuvre window, and then press the CAU S1 for S1 or S2 to open the Setting and information CAU.
- Press the Enable Increase/Decrease button to choose reset for Reset for S1 or Reset for S2.
- Press
Reset for the machine side that needs reset of the Incorrect read vision.Note: Pressing Reset resets all information, including Incorrect read vision. 
Manoeuvre window buttonCAU button S1Setting and information CAU buttonEnable Increase/Decrease button- Reset for S1
- Reset for S2
Camera Unit - Set the Height of the Frame
TT3 2000 | Equipment Status | Power must be turn OFF. Air must be turn OFF.
|
Laser radiation hazard.The electrical supply disconnecting device must be in position O (OFF) and secured with a lock before any maintenance.The vision unit contains a laser unit that could cause eye injury.
- Make sure that the Camera is set to distance A from the surface of the Conveyor chain. If the height is not according to distance A, continue with item Reference.

A = 425 mm
- Camera
- Conveyor chain
- Adjust the height of the frame with the Screw.

The illustrations show an example of setting the height of the frame.
- Screw
- Make sure that the camera is horizontal and in line with the conveyor. See Procedure Camera Unit - Set the Cover to Horizontal and Procedure Vision Unit - Set Position.
Camera Unit - Set the Cover to Horizontal
TT3 2000 | Equipment Status | Power must be turn OFF. Air must be turn OFF.
|
Laser radiation hazard.The electrical supply disconnecting device must be in position O (OFF) and secured with a lock before any maintenance.The vision unit contains a laser unit that could cause eye injury.
- Make sure that the top surface of the Cover is horizontal with, for example, a spirit level.
- If the top surface of Cover is not horizontal, set it with the Foot.

- Cover
Camera Unit - Set the Camera
TT3 2000 | Equipment Status | Program Step Step Zero |
Laser radiation hazard.The electrical supply disconnecting device must be in position O (OFF) and secured with a lock before any maintenance.The vision unit contains a laser unit that could cause eye injury.
- Press Show image.
- Let a package pass through the vision unit.
- Check the Package from top view. If the whole, or most part of the package is outside the Package from top view, the conveyor speed is faulty.Make sure that the external conveyor speed is correct. It must be 15 m/min.

- Show image
- Package from top view
- Package from side view
- Make sure that the package is centred in the image. See the illustrations.

Camera is centred.

Camera is centred.

Camera is uncentred crosswise.

The camera is uncentred lengthwise.
- If adjustment is necessary, continue with items Reference to Reference.
- Loosen the Screw with the nuts.
- To adjust the position of the camera lengthwise, move the Bracket.

- Screw
- Bracket
- To adjust the position of the camera crosswise, move Shim from one side of the Bracket to the other.Note: One shim is 1 mm thick.
- Tighten the Screw with the nuts.
- To see if the camera is correctly adjusted, repeat items Reference to Reference.

- Screw
- Bracket
- Shim
Guide - Change Photocell
TT3 2000 | Equipment Status | Power must be turn OFF. Air must be turn OFF.
|
Laser radiation hazard.The electrical supply disconnecting device must be in position O (OFF) and secured with a lock before any maintenance.The vision unit contains a laser unit that could cause eye injury.
Note: Instruction shows how to change the Photocell (transmitter), the Photocell (receiver) is changed in the same way.- Disconnect the electrical connection for the Photocell (transmitter) in the connection box.
- Remove the Screw to remove the Photocell (transmitter).
- If the transmitter is changed, set the new photocell according to Procedure Guide - Set Photocells.
- Change the photocell and assemble in the reverse order.

- Photocell (transmitter)
- Photocell (receiver)
- Screw
Guide - Set Photocells
TT3 2000 | Equipment Status | Power must be turn ON.
|
Laser radiation hazard.The electrical supply disconnecting device must be in position O (OFF) and secured with a lock before any maintenance.The vision unit contains a laser unit that could cause eye injury.
- Make sure that the photocells detect each other by checking that the little LED is lit with a red light.
- If the photocells do not detect each other, loosen the Screw. Move the photocells in the play of the holes until the LED is lit and they detect each other.
- Tighten the Screw.

- Screw
- LED
Guide - Change Cylinder
TT3 2000 | Equipment Status | Power must be turn OFF. Air must be turn OFF.
|
Laser radiation hazard.The electrical supply disconnecting device must be in position O (OFF) and secured with a lock before any maintenance.The vision unit contains a laser unit that could cause eye injury.
- Remove the L-fitting from the Cylinder.
- Remove the Nut to remove the Cylinder from the Bracket.
- Loosen the Contra nut.
- Remove the Pusher.
- Change the Cylinder.
- Open the Regulator fully. The Regulator must be adjusted according to the bottom format that is used in each individual equipment.
- Assemble in the reverse order.

- L-fitting
- Cylinder
- Nut
- Bracket
- Contra nut
- Pusher
- Regulator
Curtain - Check Curtain
TT/3 2000 | Equipment Status | Power must be turn OFF. Air must be turn OFF.
|
Laser radiation hazard.The electrical supply disconnecting device must be in position O (OFF) and secured with a lock before any maintenance.The vision unit contains a laser unit that could cause eye injury.
- Check the Curtain for any wear or damage.
- Change if necessary. See Procedure Curtain - Change Curtain.

- Curtain
Curtain - Change Curtain
TT3 2000 | Equipment Status | Power must be turn OFF. Air must be turn OFF.
|
Laser radiation hazard.The electrical supply disconnecting device must be in position O (OFF) and secured with a lock before any maintenance.The vision unit contains a laser unit that could cause eye injury.
- Remove the Screw and the Plate.
- Change the Curtain.
- Assemble in the reverse order.

- Screw
- Plate
- Curtain
Functional Description
Laser radiation hazard.The electrical supply disconnecting device must be in position O (OFF) and secured with a lock before any maintenance.The vision unit contains a laser unit that could cause eye injury.
The vision unit ejects the packages when the screw cap is not properly attached. It is a pneumatic Cylinder that ejects the packages.

- Protective cover
- Cylinder
- Laser unit
Vision Unit - Check Incorrect Read via TPOP
| Equipment Status | Power must be turn ON.
|
| Special Equipment | Keyboard |
The information about incorrect read from the vision camera can be used when evaluating the performance of the vision camera, and for troubleshooting function.- Connect a keyboard to the TPOP.
- Press F4 on the keyboard. The Technical Menu opens.
- Press the Button. The
CAU technical window opens. 
- Button
- Press the Go to sub menu button. The second page of the
CAU technical window opens.
- Compare the information about Incorrect read vision on S1 and S2 and Injection completed on S1 and S2 on S1 and S2.Note: Fallen packages are included in incorrect read. However, the proposed adjustments will not necessarily stop packages from falling and will therefore not automatically lower the amount of incorrect read.
- fallen package below the vision camera
- wrong conveyor speed (15 m/min recommended)
- no space between packages when they pass the camera
- rotated packages on the conveyor
- packages not centred in the camera view

- Injection completed on S1 and S2
- Incorrect read vision on S1 and S2
Reset of Incorrect Read Vision
- Press .
- Choose reset for Reset for S1 or Reset for S2 by pressing the Enable Increase/Decrease button.
- Press
Reset for the machine side that needs reset of the incorrect read vision.Note: Pressing Reset resets all information, including incorrect read vision. 
Manoeuvre windowCAU S1Setting and information CAUEnable Increase/Decrease button- Reset for S1
- Reset for S2
Housing - Check Curtain
| Equipment Status | Power must be turn OFF. Air must be turn OFF.
|
| Checked Item | Pass Criteria |
| Curtain | No wearNo damage |
Laser radiation hazard.The electrical supply disconnecting device must be in position O (OFF) and secured with a lock before any maintenance.The vision unit contains a laser unit that could cause eye injury.
- Check the Curtain for any wear or damage.
- If the pass criteria are not fulfilled, change the Curtain. See Procedure Housing - Change Curtain.

- Curtain
Housing - Change Curtain
| Equipment Status | Power must be turn OFF. Air must be turn OFF.
|
Laser radiation hazard.The electrical supply disconnecting device must be in position O (OFF) and secured with a lock before any maintenance.The vision unit contains a laser unit that could cause eye injury.
- Remove the Screw, the Nuts and the Plate.
- Change the Curtain.
- Assemble in the reverse order. Make sure that the two Curtain overlap each other.

- Screw
- Plate
- Curtain
- Nuts
Housing - Set Photocell
| Equipment Status | Power must be turn ON.
|
Laser radiation hazard.The electrical supply disconnecting device must be in position O (OFF) and secured with a lock before any maintenance.The vision unit contains a laser unit that could cause eye injury.
- Make sure that the Green LED on the Transmitter is lit, indicating that power is supplied.
- Make sure that the Green LED on the Receiver is lit, indicating that power is supplied.
- Remove the object to be detected.
- Make sure that the Transmitter and the Receiver are aligned.
- Make sure that the Yellow LED on the Receiver is lit or flashing, if the Yellow LED is not flashing the Transmitter and the Receiver are not aligned.
- Cover the beam with the object to be detected.
- Make sure that the Yellow LED on the Receiver is not lit and not flashing. If it is flashing, the signal is unstable. Make sure that the beam is not reflecting onto a surface around the object.
| LED | Function |
| Yellow LED | Status indicator |
| Green LED | Power indicator |

- Transmitter
- LEDGreen
- LEDYellow
- LEDGreen
- Receiver
Housing - Set Guides
| Equipment Status | Power must be turn OFF. Air must be turn OFF. Program Step |
- Loosen the four Screw.

- Screw
- Take a few packages as samples. Measure the bottom of the packages for the widest measurement.

A = Widest section of the package
- Set the distance between the guides so that it is as wide as distance A+0.5 mm.
- Tighten the four Screw.

- Screw
- Make sure that the guides are put in place and that they are the same distance from the central line as shown in the illustration.

B = C
D = E
Side Pusher - Change Cylinder
| Equipment Status | Power must be turn OFF. Air must be turn OFF.
|
Laser radiation hazard.The electrical supply disconnecting device must be in position O (OFF) and secured with a lock before any maintenance.The vision unit contains a laser unit that could cause eye injury.
- Remove the Screw.
- Remove the Cover from the Bracket.
- Remove the Tube from the Air connection.
- Remove the Air connection from the Cylinder.
- Loosen the Flange nut.
- Remove the Knob.
- Remove the Nut.
- Remove the Cylinder from the Bracket.
- Change the Cylinder.
- Assemble in the reverse order.

- Screw
- Cover
- Bracket
- Tube
- Air connection
- Flange nut
- Knob
- Nut
- Cylinder
Side Pusher - Set
| Equipment Status | Power must be turn OFF. Air must be turn OFF. Program Step |
- Install the side pusher using the right hole for the package being used.
- Valid for: Package type MidiValid for: Package type MiniInstall the pusher using the Hole.
- Valid for: Package type BaseInstall the pusher using the Hole.

- Hole
- Hole
HEPA Unit - Change HEPA Filter
| Equipment Status | Program Step |
| Special Equipment | Alkali solution Isopropanol 70% Soft cloth |
- Open the Latch and swing down the Filter housing.
- Remove the Nut and the Washer.
- Remove the Frame and the old Filter.
- Use a cloth rinsed in a mixture of water and detergent, squeeze it properly, and manually clean the inside of the Filter housing.
- Apply disinfectant on the surfaces mentioned above, by using a clean cloth sprayed with disinfectant.

- Filter housing
- Rubber strip
- Latch
- Nut
- Washer
- Frame
- Filter
Equipment damage.Install the filter correctly, avoid the guide bars from penetrating the filter.Be careful when handling and installing the filter as they may easily become deformed. Even small damages will effect the filtration.
Put the new Filter into the Filter housing with the seal surface downwards.- Install the Frame with the Nut and Washer.
- Close the Filter housing and close the Latch.
- Use a cloth rinsed in a mixture of water and detergent, squeeze it properly, and manually clean the outside of the Filter housing.
- Apply disinfectant on the surface mentioned above, by using a clean cloth sprayed with disinfectant.
Description
This chapter contains the maintenance procedures for the Package Section. The functional description on page 5-13 provides a technical description of the Package Section.Functional Description
IntroductionThe unfinished packages enter the package section from the mandrel wheels and are placed in cassettes. These cassettes transport the package through the filling and bottom sealing mechanisms. The packages are then placed on an outfeed unit and exit the machine. Note: Read the description in the specific sections for more information. Conveyor and Conveyor Drive UnitThe conveyor is made up by a number off cassettes, the unit that drives them and various equipment that guides the cassettes.The cassette conveyor is driven by two servo motors attached to two planetary gearboxes. The front and back wheels are driven by separate servomotors. The front wheel is automatically adjusted by a homing procedure. The mechanical play is by default set to 70% between the upper cassettes and 30% between the lower cassettes. The mechanical play of the front wheel can be adjusted on the TPOP. The start position of the rear wheel (the infeed wheel) is adjusted on the TPOP. The drive unit is also synchronized with the other movements in the machine through the PLC system.Bottom SealingThe Bottom sealer has two servo driven units. The first of these is the lifting unit that lifts the cassette with the filled package, the cassette stabilizer and the volume displacement cylinders. The second unit is the sealing unit with a knee mechanism that moves the sonotrodes and the dolly and assures the sealing by a pneumatic spring force. Final FolderThe function of the final folder unit is to fold the transversal seal, form it to flaps and seal them to the bottom of the package to make the package stand steadily. Outfeed UnitThe function of the discharger unit is to pull the packages from the cassettes and place them on the conveyor chain. Packages with unsealed flaps are detected by a photocell (in the machine body) and ejected. Hygiene ChamberThe hygiene chamber prevents contamination from the surrounding environment. This is done in three steps: - Spray of H2O2 peroxide solution.
- High energy UV-radiation.
- Removing peroxide residue using hot HEPA-filtrated air.
Alarms and Troubleshooting PS
Overview

| Pos. | Cross reference |
| 1 | 110304011 / 110304021 / 110304012 / 110304022, Cassette Stabiliser, Wrong Position |
| 2 | 110304411 / 110304412, HEPA Air Diffuser Plates, Wrong Position |
| 3 | 110304041 / 110304281 / 110304042 / 110304282, Bottom Seal, Converter Fault |
| 4 | 110304252, Bottom Sealing Jaws, Movement Error |
| 5 | 110304431, Main Return Valve, Wrong Position |
| 6 | 110304231 / 110304232, Outfeed Conveyor, Overload |
| 7 | 110304401 / 110304402, Aborter Door, Wrong Position |
| 8 | 110304580, Side Pusher Outfeed, Wrong Position |
| 9 | 110304071 / 110304081 / 110304072 / 110304082, Flap Seal, Wrong Temperature |
| 10 | 110304091 / 110304092, Outfeed, Ten Packages with Unsealed Flaps, S1 |
| 11 | 110304270, Discharger Error |
| 12 | 110304101 / 110304102, Outfeed, Package Left in Cassette |
| 13 | 110304241 / 110304242, Cassette Lift, Bottom Sealing Error |
| 14 | 110304211 / 110304212, Outfeed, Pusher Overload |
| 15 | 110304171 / 110304172, Cassette Lift, Filling Error |
| 16 | 110304030, Cassette Conveyor Error |
| 17 | 110304380, UV Water Clean, Low Intensity Lamp Fault |
| 18 | Alarms and Troubleshooting SRU |


| Pos. | Cross reference |
| 19 | 110304361 / 110304362, Output Module, Fuse Blown |
| 20 | 110304151 / 110304152, Volume Change, Vertical Actuator in Wrong Position |
| 21 | 110304131 / 110304141 / 110304132, Volume Change, Horizontal Cylinder in Wrong Position |
| 22 | 110304351 / 110304352, Packages Infeed into Cassette Failed |
| 23 | 110312481 / 110312482, Gas Dosing, Wrong Pressure |
| 24 | 110304050, Air Supply and Pressure to the Safety Valve |
110304011 / 110304021 / 110304012 / 110304022, Cassette Stabiliser, Wrong Position
Alarms and Troubleshoot Package Section.DescriptionThe machine is equipped with cassette stabilisers. The stabilisers centres the cassettes when the sleeves are moving from the capping station in the CAU or the stripper in the carton section.Condition for AlarmThe cassette centring movement takes more than 250ms.Troubleshooting- Check that the holder is not bent and that there are no loose screws.
- Check that the centring moves easily and is correctly set. See Procedure 5.6.4.1-1 Cassette Centring - Check.
- Check the lugs for wear and that the cylinder is not leaking air. Change if necessary. See Procedure 5.6.4.1-4 Cassette Centring – Overhaul.
- Check that the sensor has contact at the outer position.
- Check the pneumatic supply to the cylinder.
110304411 / 110304412, HEPAAir Diffuser Plates, Wrong Position
DescriptionWhen running with a TTCU cleaning, the HEPA air diffuser opens and gets a small angle.Condition for Alarm- The HEPA air diffuser plate should be closed (Production), but there is a signal.
- The HEPA air diffuser plate should be open (running with TTCU), but there is no signal.
Troubleshooting- Check that the sensor is working properly by checking the input signal to the PLC.
- Check that the cylinder is working properly. Change if necessary.
110304041 / 110304281 / 110304042 / 110304282, Bottom Seal, Converter Fault
Alarms and Troubleshoot Package Section.DescriptionWhen the bottom seal is made, the generator sends an electrical signal to the converter. The electrical signal is sent the frequency 20 kHz and is converted to oscillations energy by piezo elements.Condition for AlarmThe generator detects a signal error to or from the converters.Troubleshooting- Make a seal evaluation according to the OM Package Checks. Check for overpressure on the package to make sure that it is not a mechanical problem.
- Check that there is no gap between the sonotrode and the anvil when the servo motor is in its lowest position. If a gap is present, check the flat air cylinders in the bottom sealing housing that are compressing the package material, and perform a basic set.
- Check that there is no water in the connection.
- Check the cables between the converter and the generator, especially the quick-couplings.
- Swap the converters between the machine sides and see if the problem is transferred to the other side. If it is transferred, change the converter.
- Swap generators between the machine sides.
110304252, Bottom Sealing Jaws, Movement Error
alarms and troubleshoot Package Section.DescriptionThe bottom sealing jaws move back and forth in the bottom sealer and are driven by a servomotor. The jaws press the packaging material together just before the sealing process begins.Condition for Alarm- There is too much resistance when moving.
- Something is obstructing the movement when performing a homing, which results in an incorrect home position for the servomotor.
Troubleshooting- Push the alarm icon a second time for a more detailed alarm description.
- Check that nothing is obstructing the movement.
- Activate manual lubrication.
- Try to manually move the jaws forward and check that they move smoothly.
- Check the drive for alarm codes. If there are any alarm codes on the drive, the fault codes can be found in the MM. See Procedure 7.5.6-1 Servo System - General Troubleshoot.
- If something is obstructing the way when performing a homing, the home position could be set wrong. Step down the machine to Pre-heating and disconnect and connect the feedback cable to the servomotor.Note: Before doing this, check for alarm codes on the drive.
110304431, Main Return Valve, Wrong Position
DescriptionThe main return valve transfers the product or cleaning liquid back out from the machine to process. The main return valve is used during CIP, Quick Rinse, Product Drain, and Tank Drain.Condition for Alarm- The valve should be opened, but the sensor on the lid gets no signal.
- The valve should be closed, but the sensor gets no signal.
Troubleshooting- Check that the valve lid is correctly assembled.
- Check that the sensor detects the position of the valve.
- Check that the sensor is not positioned too far in or too far out.
- If the lid “jumps” up repeatedly, try changing the air filter that is attached on the side of the valve. If that does not help, put two straps on the lid to hold it down as a temporary solution. Order a new part and replace the defected.Note: First make sure the sensor is not positioned too far in.
- Check the input signal to the PLC via EM.
110304231 / 110304232, Outfeed Conveyor, Overload
DescriptionThe outfeed conveyor belt transports the packages from the machine to the outer conveyor.Condition for Alarm- The frequency converter does not send a ready signal.
- The frequency converter does not send an active signal.
Troubleshooting- Check that nothing is obstructing the conveyor.
- Check that the conveyor is not too tight or loose.
- Check for an error code on the frequency converter.
- Check the fuse.
110304401 / 110304402, Aborter Door, Wrong Position
DescriptionThe aborter door should be closed when the TTCU re-uses the cleaning liquid during the External Cleaning.Condition for AlarmThe doors are closed, but the sensor does not get a signal.Troubleshooting- Check that the doors are closed.
- Check that the sensor is getting a signal that the doors are closed.
- Check that the alarm disappears when placing a metal piece in front of the sensor.
- Change the sensor.
110304580 / 110304581 / 110304582, Side Pusher Outfeed, Wrong Position
Valid for Dev. Step 1900 / 2000DescriptionThe side pusher is the final step in the machine. It pushes the packages on to the inner conveyor. The side pusher is driven by a servomotor.Condition for Alarm- Something is obstructing the movement of the pusher.
- Something is obstructing the movement when performing a homing, which results in an incorrect home position for the servomotor.
Troubleshooting- Check the belt on the linear unit.
- Check that nothing is obstructing the side pusher.
- Check the drive for alarm codes. If there are any alarm codes on the drive, the fault codes can be found in the MM. See Procedure 7.5.6-1 Servo System - General Troubleshoot.
- At homing, the position can change if the shafts for the cam roller are damaged.
- If something is obstructing the way when performing a homing, the home position could be set wrong. Step down the machine to Pre-heating, then disconnect and connect the feedback cable to the servomotor.Note: Before doing this, check for alarm codes on the drive.
- Check that no cassettes are damaged.
110304071 / 110304081 / 110304072 / 110304082, Flap Seal, Wrong Temperature
Alarms and Troubleshoot Package Section.DescriptionTo seal the flaps against the bottom of the package, the machine heats up part of the flaps to melt the outer layer of plastic. The flaps are then pressed against the package and cooled down.When stepping up to motor running there is a 25s timer. The temperature for the flap sealing oven must be greater than the set minimum value before stepping up to production.Condition for AlarmThe temperature deviates more than 20°C from the set value for more than 5s during production.Troubleshooting- Check the fuse.
- If there is an open circuit or if the temperature sensor is broken, it shows 1372°C on the TPOP.
- Make sure that the air temperature is 400-410°C.
- Check that the flap sealing nozzle is not clogged. See Procedure 5.4.4-1 Flap Heater - Check.
- Check the thermocouple and the distance. See Procedure 5.4.4-4 Flap Heater - Fit Thermocouple.
- Check the air pressure:2.5±0.5bar for Base.2.0±0.5bar for Midi/Mini/Micro.
- Check the heating element. If the air is lost, the heating element can be burnt.
- Check for short circuit windings.
110304091 / 110304092, Outfeed, Ten Packages with Unsealed Flaps, S1
Alarms and Troubleshoot Package Section.DescriptionTo seal the flaps against the bottom of the package, the machine heats up part of the flaps to melt the outer layer of plastic. The flaps are then pressed against the package and cooled down.Condition for AlarmIf 5x2packages get wasted because of bad flap sealing, the machine steps down. Note that there is a count down function for this alarm. For example, if the machine produces 4x2packages and then begins to produce packages with good flap sealing, the counter counts down until it reaches zero.Troubleshooting110304270, Discharger Error
alarms and troubleshoot Package Section.DescriptionThe discharger transfers the packages from the cassettes and puts them down in front of the pusher. The discharger is driven by a servomotor and connected to a linear unit to move it up and down. The gripper fingers are moved by pneumatic force.Condition for Alarm- There is too much resistance when the discharger is moving.
- Something is obstructing the movement when performing a homing, which results in an incorrect home position for the servomotor. The home position it set mechanically.
- There is a problem with the linear unit or belt.
Troubleshooting- Push the alarm icon a second time for a more detailed alarm description.
- Check that nothing is obstructing the movement.
- Check that mechanical parts are correctly aligned.
- Check that the lubrication is sufficient and not absent.
- Check the bushings.
- Check the belt on the linear unit.
- Check the drive for alarm codes. If there are any alarm codes on the drive, the fault codes can be found in the MM. See Procedure 7.5.6-1 Servo System - General Troubleshoot.
110304101 / 110304102, Outfeed, Package Left in Cassette
DescriptionTwo gripper fingers transfer packages from the cassette. The gripper fingers pull the packages out from the cassette and put them in front of the pusher.A photocell unit, active during sector value800-1100, detects if the gripper fingers fail to pull the packages out from the cassette.Condition for AlarmThe gripper fingers cannot pull the packages from the cassette.Troubleshooting110304241 / 110304242, Cassette Lift, Bottom Sealing Error
Alarms and Troubleshoot Package Section.DescriptionThe cassette lift lifts the packages up during the transversal sealing.Condition for Alarm- There is too much resistance when the cassette lift is moving up and down.
- Something is obstructing the movement when performing a homing, which results in an incorrect home position for the servomotor.
Troubleshooting- Push the alarm icon a second time for a more detailed alarm description.
- Check the belt on the linear unit.
- Check that nothing is obstructing the movement.
- Check the drive for alarm codes. If there are any alarm codes on the drive, the fault codes can be found in the MM. See Procedure 7.5.6-1 Servo System - General Troubleshoot.
- If something is obstructing the way when performing a homing, the home position could be set wrong. Step down the machine to Pre-heating and disconnect and connect the feedback cable to the servomotor.Note: Before doing this, check for alarm codes on the drive.
110304211 / 110304212, Outfeed, Pusher Overload
DescriptionThe outfeed pusher pushes the packages to the inner conveyor or, if there is a side pusher, to the plate above the inner conveyor.Condition for AlarmThe outfeed pusher fails to move from the inner to the outer position in less than 600ms, three times in a row.Note: After an external cleaning this alarm can occur up to three times.Troubleshooting110304171 / 110304172, Cassette Lift, Filling Error
alarms and troubleshoot Package Section.DescriptionThe cassette lift lifts up the cassette during the filling of the package.Condition for Alarm- There is too much resistance when the cassette lift is moving.
- Something is obstructing the movement when performing a homing, which results in an incorrect home position for the servomotor. The home position it set mechanically.
- There is a problem with the linear unit or belt.
Troubleshooting- Push the alarm icon a second time for a more detailed alarm description.
- Check the belt on the linear unit.
- Check that nothing is obstructing the movement.
- Check that mechanical parts that are correctly aligned.
- Check that the lubrication is sufficient and not absent.
- Check the drive for alarm codes. If there are any alarm codes on the drive, the fault codes can be found in the MM. See Procedure 7.5.6-1 Servo System - General Troubleshoot.
- If something is obstructing the way when performing a homing, the home position could be set wrong. Step down the machine to Pre-heating, then disconnect and connect the feedback cable to the servomotor.Note: Before doing this, check for alarm codes on the drive.
110304030, Cassette Conveyor Error
alarms and troubleshoot Package Section.DescriptionThe conveyor contains cassettes, which holds and transports the packages during several functions.Condition for Alarm- The conveyor is moving with a high force.
- The space between the cassette and conveyor rail is too small.
- To much friction between the cassettes and conveyor rail. During an external cleaning the material gets hot and expands.
- A package is stuck in the package section.
Troubleshooting- Push the alarm icon a second time for a more detailed alarm description.
- Check the distance between the cassette and the conveyor guide rail. If necessary, set the guide rails. See Procedure 5.2.4.1-1 Guide Rails - Set.
- Check the distance between the cassettes
- Check that the cassette lubrication is sufficient. Try increasing it a little.
- Check that no parts are stuck between the cassette and star wheel.
- Check that the volume displacement cylinder, both upper and lower, is working correctly and is not stuck in a cassette during production.
- If this happens during a volume change, check that the volume change cylinder is not stuck in a position where it obstructs the conveyor movement.
- Check if the cassette centring cylinder is slow and then check the setting of the cassette lift. See Procedure 5.3.10-1 Cassette Lifter, Centring - Set Height and Centring in the MM.
- Check that the centring of the cassette stabilisers works smoothly and is correctly set. See Procedure Cassette Centring - Check in the MM.
110304380, UV Water Clean, Low Intensity Lamp Fault
DescriptionThe UV lamp sterilizes the cassette lubrication water for both machine sides.Condition for AlarmThe sensor, attached to the UV lamp housing, is getting a weak light from the lamp.Troubleshooting110304361 / 110304362, Output Module, Fuse Blown
DescriptionThis is a summary alarm for all electronic fuses for the output modules in the Package DeviceNet nodes.Condition for AlarmA DeviceNet output module in the package section is overloaded.Troubleshooting- Check that the electrical connections are properly connected.
- Switch the DeviceNet node OFF and ON. +24V turn off to ADN module and all the EP24 modules.
- Change the ADN DeviceNet scanner module.
- Tighten all unused connections.
110304151 / 110304152, Volume Change, Vertical Actuator in Wrong Position
DescriptionThe volume washer position is adjusted, up or down, depending on package volume.Condition for AlarmThe volume washer is not in position within 10seconds.Troubleshooting110304131 / 110304141 / 110304132, Volume Change, Horizontal Cylinder in Wrong Position
DescriptionOn volume change, the volume change cylinder moves the volume washer in or out from the cassette. There are two sensors that detect the end positions, one for inner and one for the outer position.Condition for AlarmIt takes longer than 2.5seconds to change from inner to outer position and vice versa.Troubleshooting110304351 / 110304352, Packages Infeed into Cassette Failed
DescriptionWhen the sleeve enters the cassette, the cassette centring secures the cassette in a position aligned with the sleeve. This ensures that the sleeve moves all the way into cassette.There is a fibre optic sensor, mounted on the infeed hatches, which has one sender and one receiver. This sensor detects if the package fail to go all the way into the cassette.Condition for AlarmThe package is not properly placed in the cassette.Troubleshooting110312481 / 110312482, Gas Dosing, Wrong Pressure
DescriptionSome products will be affected by oxygen in the head-space of the package. Vitamins, colour and taste can be affected. If the oxygen level is reduced, from the normal 21% to about 8-10%, the shelf life of the product can be increased considerably. The gas dosing system does that by replacing the oxygen in the head-space with substitute gas.Gas at 4-6bar passes from the supply unit, through a connection at the filling platform, to a valve block in the front of the machine. The valves switch between gas dosing and compressed air. A proportional valve reduces the gas pressure to the value that is set in the PLC. This is about 2.5bar during production.The valves will be switching on and off during production.Condition for AlarmThe gas dosing pressure is outside the PLC limits.Troubleshooting- Check the manometers in the front of the machine.
- Check that the valves switch fast enough between on and off.
- Check that the gas dosing valves work properly.
110304050, Air Supply and Pressure to the Safety Valve
Troubleshooting- Make sure that the air pressure is set correctly on the main ramp. See Procedure 6.6.1-1 Pneumatic Supply - Set Pressure (Festo, Mecman), in the MM.
- Make sure that the manual valve before the safety valve is open. See Procedure Safety Air Valve - Description.
- Make sure that the manometer on the safety air valve shows at least 6bar. If it shows < 3bar, there is an air leakage problem, and the safety air valve will not fully pressurise the system. Check for air leakage.
- If the safety air valve shows 6 bar, there should be a signal from the pressure guard. Check the electrical connection to the pressure guard and the Point I/O input. The pressure guard is factory set and should normally not be adjusted.
Safety Air Valve - Description
General
The following table describes the functions performed by the Safety air valve.| Machine status | Phase | Function performed by the Safety air valve | Comment |
| Air on | 1 | The pneumatic system is exhausted of all air. | |
| 2 | The pneumatic system is pressurised to 50% of the incoming pressure | If the air pressure is impeded by leakage in the system, the Safety air valve will not continue to phase 3 |
| 3 | The pneumatic system is pressurised to 100% of the incoming pressure | |
| air off | Exhaust | The pneumatic system is quickly exhausted of all air | This function is also performed if an emergency stop is actuated, or if a door is opened |
The Manual open/close valve is normally in the open position.
- Manual open/close valve
- Safety air valve
Functional Description
The conveyor unit holds and transports the packages during filling, transversal sealing and flap sealing. The packages are delivered to the conveyor unit from the mandrels and then to the discharge unit.Volume Plates - Check
| Equipment Status | Program Step |
Without removing the volume plates from the cassettes, check that all volume plates are fixed into their positions in the cassettes, and that they are undamaged.Cassettes - Check by Straightening Tool
| Special Equipment | Template TP No. 1025194-0003 Guiding arbor Base TP No. 989163 Guiding arbor Midi TP No. 1506701 Guiding arbor Mini STD TP No. 1295479 Guiding arbor Micro TP No.1590177 Guiding arbor Mini V TP No.3440371 Template Base TP No. 2704220 Template Base TP No. 2704222 Template Base TP No. 2704223 Template Base TP No. 2704224 Template TP No. 2710959 |
Note: All the cassettes have to be removed from the conveyor and then checked with the aid of the straightening tool.Note: Remove the cassettes four by four and reinstall, according to Procedure .
- Check that the correct Guiding arbor is installed into the tool.
| Guiding arbor | Base | Midi | Mini STD | Mini V | Micro |
| TP-number | 989163 | 1506701 | 1295479 | 3440371 | 1590177 |
- Fix the Cassette in position with the Eccentric lock.
- Push down on the Lever. The Guiding arbor should slide smoothly through the Cassette without any restriction. Check both sides of the cassette.

- Guiding arbor
- Cassette
- Eccentric lock
- Lever
- If the Guiding arbor does not slide smoothly through the Cassette, straighten the cassette according to the following steps.
- Adjust the cassette with the aid of an aluminium bar. Adjust and check until it is straight. See the illustration below.Note: If the cassette is too damaged to be adjusted, it has to be replaced.
- After straightening a Cassette, or when changing parts of a Cassette, check that the distance A between the baskets is within the correct limits (min. / max of the Template G). Use the correct Template G according to the table below.
| Template G | Base | Midi | Mini | Micro |
| TP-number | 2704220 | 2704222 | 2704223 | 2704224 |
- Check with the distance B between the two Angle plate with the Template, TP-number 2710959. The distance must not be less than the Template is wide.
- When refitting the cassettes into the conveyor, check all volume plates and make sure that they are:
- Fixed into their positions in the cassettes.
- Turned the correct way.
- Undamaged.

- Cassette
- Template G
- Angle plate
- Template
Cassettes - Check Links
- Check the four measurements, that are listed below, on all the links.
- Change any links that are too worn.
- Change any links that are cracked or damaged.
| Dimensions | Measure limit |
| A | Min. 49.0 mm |
| B | Max. 8.5 mm |
| C | Max. 0.7 mm |
| D | Min. 147.0 mm |
Note: It is recommended to change all the links at the same time. - Turn the casette upside down and inspect the Shaft for wear. Change the Shaft if necessary. See Procedure Cassettes - Change.

- Shaft
Cassettes - Change
| Equipment Status | Program Step |
Note: It may be necessary to loosen the transport-wheel. Do this according to - Remove the Holder-block.
- Close the doors and inch the machine until the front edge of a Cassette is even with the rear edge of the Cassette lift fork.
- Remove the Screw and use it to fasten the Excenter handle.
- Raise the “bottom sealing cassette lift” by turning the Excenter handle.

- Holder-block
- Cassette
- Cassette lift fork
- Screw
- Excenter handle
- Change four cassettes.
- Close the doors and inch the machine until the front edge of the next Cassette is even with the rear edge of the Cassette lift fork.
- Change the next four cassettes.
- Repeat step f) to g) until you have changed all the cassettes.
- Remove the Excenter handle and fit the Holder-block.
- Make sure all cassettes and volume plates are correctly fit in their positions.

- Holder-block
- Cassette
- Cassette lift fork
- Screw
- Excenter handle
Cassettes - Loosen the Transport Wheels
| Equipment Status | Program Step |
Risk of crushing and cutting.Always secure the loosened transport wheel before starting any work.The weight of the cassettes can cause the loosened transport-wheel to turn.
- Measure and note down the gap A, between the cassettes. This will make it easier to reset the gap, after the service work is done.
- Loosen the Transport-wheel or Transport-wheel by loosening the clamp unit that holds it.
- Turn the Transport-wheel or Transport-wheel and remove as many cassettes as necessary.
- Secure the loosened transport-wheel by wedging a suitable Tool between the transport wheel and the Guide rail.Note: The illustration only shown an example of the kind of tool that can be uses and where to place it. The Tool can be placed both above and below the guide rails 4 and on both wheels.

- Transport-wheel
- Transport-wheel
- Tool
- Guide rail
- Carry out the service-work that has to be done.
- If Transport-wheel has been loosened, reset and tighten the clamp unit according to Cassette Assemble - Set.
- If Transport-wheel has been loosened, reset the previously noted gap A, and tighten the clamp unit according to Cassette Assemble - Set.
- Make sure that all the cassettes and volume plates are correctly fitted in their positions.

- Transport-wheel
- Transport-wheel
- Tool
- Guide rail
Volume Plates - Change
New Procedure 5.2.3-7 | Equipment Status | Program Step |
Change the volume plates.Note: The volume plates for the opening Nallo are asymmetrical. Make sure to place them according to the table and illustration.
- 3445976
- 3445975
Guide Rails - Set
| Equipment Status | Program Step |
| Special Equipment | Templates TP No. 2758018 (1481936), 2734160, 915329-0101 |
- Adjust the guide/rail (6) with the template 2734160, horizontally and vertically. (Distance A = 51.5 ±0.2 mm.) Adjust by the screws (7) and (8).
- Set the distances between rails (4) and (5) with the two templates 2758018 (distance B= 51 ±0.2 mm). Adjust by the screws (9).
- Put a pair of cassettes on the rails and check gaps C= 1-2 mm, between the holder (10) and the plastic-link of the cassettes. Adjust by the screws (11). If the holder has to be moved, carefully check that it is still centred sideways to the plastic-link.
- Centre the curved guides (2) to the transport-wheels (1), with the template 915329-0101.
- Loosen the screws (12) and set the distance G = 151.0 +0.5/-0.0 mm.
- Retighten the screws.
Lower Volume Displacers - Check
| Equipment Status | Program Step STEP ZERO |
Risk of crushing. Be careful when working near the moving parts.The machine contains moving parts that can crush.
Use the air service tool to perform the instructions in this procedure. See Air Service Tool Description.- Check the Button for damage.If necessary, change the buttons. See Procedure Lower Volume Displacers - Overhaul.
- Check for air leakage at the Cylinder, by the pistons, and by the push-in fittings.If necessary, overhaul the cylinder. See Procedure Lower Volume Displacers - Overhaul.

- Button
- Cylinder
Lower Volume Displacers - Check
| Equipment Status | Program Step STEP ZERO |
Risk of crushing.Be careful when working near the moving parts.The machine contains moving parts that can crush.
Use the air service tool to perform the instructions in this procedure. See Air Service Tool Description.- Check the Bow/Pressure Device for damage. If necessary, change the bows/pressure devices.
- Make sure that the Bow/Pressure Device are parallel with the side of the cylinder house. See the illustration.
- Check for air leakage at the Cylinder, by the pistons, and by the push-in fittings. On Festo machines, use the air service tool. See Air Service Tool DescriptionIf necessary, overhaul the cylinder. See Procedure Lower Volume Displacers - Overhaul.

- Bow/Pressure Device
- Cylinder
Lower Volume Displacers - Set
Fieldtest OK Mini V move changes to original topic in MM after fieldtest! | Equipment Status | Program Step STEP ZERO |
Risk of crushing.Be careful when working near the moving parts.The machine contains moving parts that can crush.
- Set the distance A (same on both sides) between the Pressure device and the Cassette, according to the table. To adjust the distance:
- When measuring the distance A: Use 2 feeler gauges to centre the Cassette, one on each side.
- loosen the Nut, rotate the Pressure device, and tighten the Nut.
| Base | Midi | Mini | MiniV | Micro |
| A (mm) | Not adjustable | 4.0 ±0.5 | 5.0 ±0.5 | 4.5 ±0.5 | 5.0 ±0.5 |
- Centre the Pressure device in the holes of the Cassette and align with the machine creases.
- During production, check that the Pressure device enter the Cassette.

- Pressure device
- Cassette
- Nut
Lower Volume Displacers - Overhaul
| Equipment Status | Program Step STEP ZERO |
Risk of crushing. Be careful when working near the moving parts.The machine contains moving parts that can crush.
- Disconnect the Pneumatic hose.
- Remove the Screw, the Plate, and the Cylinder.
- Put the Cylinder on a clean working area.

- Pneumatic hose
- Screw
- Plate
- Cylinder
- Remove the Push-in fitting, the Button, and the Screw from the Cylinder.
- Assemble in the reverse order with a new Cylinder.If necessary, change the Push-in fitting and the Button.
- Make sure that the cylinder moves smoothly and that no air is leaking from the pneumatic hose connections.Note: If there is a leakage, check if the pneumatic hoses are damaged. If necessary, cut them.

- Cylinder
- Push-in fitting
- Button
- Screw
Functional Description
- Lifting unit that lifts the cassette, the filled package, the cassette stabilizer and the volume displacement cylinders. This unit is driven by a Servomotor and a Belt drive.
- Sealing unit with a knee mechanism that moves the US-horn and the Anvil and assures the sealing by a pneumatic spring force. This unit is driven by a Servomotor and a Ball screw.

- Lifting unit
- Servomotor
- Belt drive
- Sealing unit
- US-horn
- Anvil
- Servomotor
- Ball screw
Knee Mechanism of the Sealing Unit
The Ball screw is driving a linear guided Yoke in vertical direction. To make the linear jaw movement between the anvil and the US-horns, the yoke is linked with Link arm to:The knee mechanism unit is fixed to the frame with Linear bearing and Linear bearing.The movements are shown in the illustration below.
- Ball screw
- Yoke
- Link arm
- Anvil
- Pneumatic spring carriage
- Pneumatic spring carriage
- Overtravel carriage
- Linear bearing
- Linear bearing
Folding
During the dwell time of the cassette conveyer, the folding and sealing take place. A synchronized movement of the lifter and knee mechanism makes the folding. This combined movement follows a predicted Folding curve.
- Folding curve
The diagram below shows the whole sequence of the cassette conveyer index, cassette lifter and knee mechanism.
- Seal
- Cool
- Conveyor index
- Cassette lifter
- Knee mechanism
Sealing Functionality
The US-horn are clamped with a Mechanical joint to Pneumatic spring carriage and Pneumatic spring carriage which can move independently from each other. On these pneumatic spring carriages there are four Pneumatic membrane that are always pressurized with the setting from a Regulator. The membranes are pressing against the Overtravel carriage.
- US-horn
- Mechanical joint
- Pneumatic spring carriage
- Pneumatic spring carriage
- Pneumatic membrane
- Regulator
- Overtravel carriage
The three carriages move together as a group. When the knee mechanism is moving down, the force is almost infinite when the Link reaches its nearly straight position. At this point the mechanism reaches an end point due to that the distance between the anvil and US-horns is zero. This is basic setting for the end point of the servomotor.When the folded package is squeezed between the Anvil and the US-horn there will be a distance D of 0.4 mm compressed paperboard. The Overtravel carriage moves then into the Pneumatic membrane leaving a distance E of 0.35 mm in-between the Pneumatic spring carriage and Pneumatic spring carriage and the Overtravel carriage. The force in the system is now set to the pneumatic pressure in the membranes and the sealing pulse can be performed.
D = 0.4 mm
E = 0.35 mm
- US-horn
- Pneumatic spring carriage
- Pneumatic spring carriage
- Pneumatic membrane
- Overtravel carriage
- Link
- Anvil
Link Bearings - Change
| Equipment Status | Program Step |
Note: This operation is possible to carry out with Bottom Sealing in place in the machine.- Remove the cover, see Procedure Bottom Sealing Unit - Remove (items a and b).
- Remove the Screw and Washer on all the links.
- Remove the four links.
- Note the position of the spring Washer.
- Check that the Fitting bolt are tightly fastened and that there is loctite on the threads. If the Fitting bolt are loose or if there is no loctite on the threads, apply loctite to them and tighten them.
- Change the bearings.
- Assemble in the reverse order; spring washer in correct position.

- Screw
- Washer
- Washer
- Fitting bolt
Ball Rail Unit - Change
| Equipment Status | Program Step |
Note: This operation is possible to carry out with Bottom Sealing in place in the machine.- Remove the Screw and Screw.
- Lift up the lubrication plate and fix it to the Beam, using stripes.
- Remove the Screw and lift out the Ball rail.
- Put the new ball rails into the machine and note that the lubrication hole, with the O-ring, should be pointing backwards in the machine direction.
- Align the Ball rail to the Reference surface, then tighten the Screw.
- Put the lubrication plate back; first tighten the Screw, then the Screw.

- Screw
- Screw
- Beam
- Screw
- Ball rail
- O-ring
- Reference surface
Converter - Description
There are two versions of converters for the Tetra Top Machine.The versions can be identified by their properties, as described below.Version 1 has Arrow.
- Arrow
Version 2 has a Range marker.In version 2, the internal wires have a predetermined routing to avoid damage while turning the sonotrode.
- Range marker
Seals - Check
| Equipment Status | Program Step |
- Check at the outer and inner tie bar that no oil is leaking out through the Seal and Seal. If leakage is detected, change seals according to Seals - Change.

- Seal
- Seal
Sonotrode, Folding Plate - Set
| Equipment Status | Program Step Step Zero |
| Special Equipment | Tool TP No. 3601927-0000 Torque wrench, 1/2" (≥ 220 Nm) |
| Consumables | Penetrating lubricant Klüberpaste 344417-0000 |
- Make sure that the Sonotrode is parallel to the Folding plate by comparing distance A to distance B. If they are not the same, proceed to item Reference.Note: The distance between the Sonotrode and the Folding plate cannot be changed. The only important setting is that the distances A and B are the same.

A = B ± 0.4 mm
- Sonotrode
- Folding plate
Risk of damage to the equipment.Always use penetrating lubricant on the threads before loosening the
Ring.Do not use a hammer on the
Sonotrode or the
Ring. The impacts can damage the ceramic discs inside the converter. Both the
Ring and the converter are made of stainless steel and can easily seize.
- Remove the Converter from the machine. Put the Converter on a workbench.
- Put the Converter in a vice. Make sure to not damage the identification tag.
- Check the holes on the Ring. If the holes are worn, remove the sonotrode. See Procedure Sonotrode - Change, and perform item Reference. If the holes are in good condition, perform item Reference.
- Use a drilling machine with a drill the same size as the holes to drill the worn holes.

- Sonotrode
- Shaft
- Converter
- Ring
- Fit the Tool into the holes on the ring.
- Place a 1/2"inch wrench in the Square hole of the tool. Loosen the Ring.

- Sonotrode
- Ring
- Square hole
- Tool
- Use the adjustable wrench to adjust the Sonotrode. Make sure the Sonotrode is parallel with the Folding plate.
- Use the adjustable wrench to hold the Sonotrode in place. Make sure the Sonotrode is still parallel with the Folding plate. Set a 1/2" torque wrench to 220Nm and use the Tool to tighten the ring.
- Install the Converter with the Sonotrode in the machine.
- Set the sonotrode and anvil. See Procedure5.3.6-3 Sonotrode and Anvil - Set (Align).
- Set the folding plate. See Procedure5.3.7-2 Folding Plate - Set.

- Sonotrode
- Folding plate
- Converter
- Tool
Sonotrode and Anvil - Set (Align)
| Equipment Status | Program Step |
| Special Equipment | Assembly tool TP No. 2633197-0101 Ruler |
Note: The Cable must be twisted according to the illustration to avoid too sharp bends during production.- Pressurise the air cylinders to a minimum of 2 bar with the Regulator.
- Loosen the Screw, and retighten them by hand.
- Loosen the Screw.
- Lower the Yoke to their mechanical stop.
- Put a Ruler on top of the Sonotrode. Align the Sonotrode to one another.

- Cable
- Regulator
- Screw
- Screw
- Yoke
- Ruler
- Sonotrode
- Adjust the sonotrodes sideways:
- Adjust Base in the direction shown in illustration E;
- Adjust Midi/Mini/Micro in the direction shown in illustration F.Note: The sonotrodes are moved in the same direction on both sides of the machine.
- Fit the Assembly tool (2633197-0101), to fix the sonotrodes to the anvil, and tighten the Hand-wheel. Make sure that the Assembly tool is tightened to the mechanical stop or the settings will be incorrect.
- Move the Sonotrode bracket to a centred position around the Screw. The screws must be centred in the hole in the forwards and backwards directions.
- Tighten the Screw.

Top left: Illustration ETop right: Illustration F
- Assembly tool
- Hand-wheel
- Sonotrode bracket
- Tighten the screws cross-wise, in at least three steps, to avoid impairing of the setting.
- Remove the assembly tool.
- Run the machine and check the position of the pressure mark on the transversal seal of the packages, the correct measurements, including distanceA, are shown on the illustration.
- If the pressure marks on the transversal seal of the packages are not centred, readjust the sideways centring of the sonotrodes.

A = 9 mm ±1 mm
Seals - Change
| Equipment Status | Program Step |
- If mounted, remove the Anvil.
- Lubricate the inner surface of the seals. The inner surface is lubricated to avoid noise from the rods during production.
- Fit Seal and Seal.
- Turn the outer Shaft by 10°.
- The function of the two outer Seal is to tighten inwards (to prevent oil to leak out from the bottom sealing house into the hygienic chamber).
- The function of the three Seal in the middle is to tighten outwards (to prevent cleaning solution to leak into the bottom sealing house).
- Hence, the seals are to be fit differently, in accordance with the illustration.
- Fit the Sonotrode holder.
- Put the Anvil back, and thereafter, tighten the seals by their covers.
- Fit the sonotrodes and set according to Sonotrode and Anvil - Set (Align).

- Anvil
- Seal
- Seal
- Sonotrode holder
- Shaft
Sonotrode - Change
| Equipment Status | Program Step |
| Special Equipment | Tool TP No. 3601927-0000 Torque wrench, 1/2" (≥ 80 Nm) |
| Consumables | Penetrating lubricant |
Risk of damage to the equipment. Both the ring and the converter are made of stainless steel and can easily seize.
- Remove the converter from the machine and put it on a workbench. Do not put the converter in a vice.
- Remove the Bolt and the Folding plate.

- Bolt
- Folding plate
Risk of damage to the equipment.Do not use a hammer on the
Sonotrode. The impacts can damage the ceramic discs inside the converter.
- Hold the Shaft with the Tool and use an adjustable spanner to turn the Sonotrode counter-clockwise.
- Remove the old Sonotrode.

- Shaft
- Sonotrode
- Tool
- Install a new Sonotrode.
- Make sure that the converter is free to move on the bench.
- Hold the Sonotrode with an adjustable spanner. Hold the Shaft with the Tool. Set a 1/2" torque wrench to 80Nm and put it in the square hole of the Tool. Tighten the Sonotrode to the Shaft.

- Shaft
- Sonotrode
- Tool
- Install the Folding plate with the Bolt.
- Set the Sonotrode and the folding plate according to Sonotrode, Folding Plate - Set.
- Install the converter in the machine.
- Set the Sonotrode and the anvil according to Procedure Sonotrode and Anvil - Set (Align).
- Set the folding plate. See Sonotrode, Folding Plate - Set.

- Bolt
- Folding plate
- Sonotrode
Sonotrode - Turn
| Equipment Status | Program Step Step Zero |
| Special Equipment | Tool TP No. 3601927-0000 Torque wrench, 1/2" (>220Nm) |
| Consumables | Klüberpaste 344417-0000 Silicone grease 344477-0000 Penetrating Lubricant |
Note: The sonotrode is a very delicate machine part. This instruction must be performed with great caution.- Make sure to know which version is installed in your machine. See Converter - Description
- Remove the converter from the machine and put the converter in a vice.
- Remove the Bolt and the Folding plate.

- Bolt
- Folding plate
Risk of damage to the equipment.Do not use a hammer on the
Sonotrode. The impacts can damage the ceramic discs inside the converter.
- Hold the Shaft with the Tool. Use an adjustable spanner to turn the Sonotrode counter-clockwise.
- Remove the Sonotrode.

- Shaft
- Tool
- Sonotrode
Risk of damage to the equipment.Do not use a hammer on the
Sonotrode or the
Ring. The impacts can damage the ceramic discs inside the converter.
- Check the holes on the Ring. If the holes are worn, perform item Reference. If the holes are in good condition, perform item Reference.
- Use a drilling machine with a drill the same size as the holes to drill the worn holes.

- Converter
- Ring
Risk of damage to the equipment. Both the
Ring and the
Converter are made of stainless steel and can easily seize.
- Loosen the Cable gland.
- Use penetrating lubricant between the Converter and the Ring.
- Fit the Tool into the holes on the Ring.
- Place a 1/2 inch wrench in the Square hole of the Tool. Unscrew the Ring.Note: Make sure not to turn the Shaft. Turning the Shaft can damage the wires inside the converter.

- Shaft
- Tool
- Ring
- Cable gland
- Square hole
- Remove the old O-ring.
- Put Silicone grease 344477-0000 on a new O-ring and install it on the Ring.

- Ring
- O-ring
Risk of damage to the equipmentAlways check the cables in the
Converter before turning the
Sonotrode 180º in order to not stretch the cables.The cables in the
Converter can be damaged.
- Put alcohol or soap water on the Cable.
- Gently feed the cable through the Cable gland while lifting the Shaft.
- Gently lift the Shaft until the Wire inside the converter housing become visible.

- Shaft
- Cable gland
- Cable
- Wire
- Remove the old O-ring.
- Put Silicone grease 344477-0000 on a new O-ring and install it inside the converter housing.

- O-ring
- Install the Sonotrode on the Shaft. Tighten the Sonotrode by hand.
- Make sure to turn the Sonotrode 180 degrees in a direction that does not stretch the cables. Make sure that the worn side of the Sonotrode is turned towards the Cable gland.
- Apply Klüberpaste 344417-0000 on the Threads.
- Apply a thin layer of Klüberpaste 344417-0000 on the Surface.

- Shaft
- Sonotrode
- Cable gland
- Threads
- Surface
Risk of damage to the equipmentMake sure to not damage or squeeze the cables inside the converter housing during reassembly.The cables in the converter can be damaged.
- Put alcohol or soap water on the Cable.
- Gently feed the cable through the Cable gland while lowering the Shaft.
- Lower the Shaft and the Sonotrode into the converter housing.
- Tighten the Ring loosely by hand.
- Tighten the Cable gland.

- Shaft
- Sonotrode
- Ring
- Cable gland
- Cable
- Make sure that the converter is free to move on the bench. Hold the Sonotrode with an adjustable spanner. Set a 1/2" torque wrench to80Nm and tighten the Sonotrode to the Shaft with the Tool.

- Shaft
- Tool
- Sonotrode
- Put the Converter back in the vice.
- Install the Bolt and the Folding plate.

- Bolt
- Folding plate
- Converter
- Make sure that the Sonotrode is parallel to the Folding plate by comparing distance A to distance B.Note: The distance between the Folding plate and the Sonotrode can not be changed. The only important setting is that the distances A and B are the same.

A = B ± 0.4 mm
- Folding plate
- Sonotrode
- Use the adjustable wrench to hold the Sonotrode in place. Make sure the Sonotrode is still parallel with the Folding plate. Set a 1/2" torque wrench to 220Nm and use the Tool to tighten the ring.

- Folding plate
- Tool
- Sonotrode
- Install the converter with the Sonotrode in the machine.
- Set the Sonotrode and the anvil. See Procedure Sonotrode and Anvil - Set (Align).
- Set the folding plate. See Procedure Folding Plate - Set.
Sonotrode - Turn
| Equipment Status | Program Step Step Zero |
| Special Equipment | Tool TP No. 3601927-0000 Torque wrench, 1/2" (>220Nm) |
| Consumables | Penetrating Lubricant |
- Make sure to know which version is installed in your machine. See Converter - Description
- Remove the converter from the machine and put the converter in a vice.
- Remove the Bolt and the Folding plate.

- Bolt
- Folding plate
Risk of damage to the equipment.Do not use a hammer on the
Ring. The impacts can damage the ceramic discs inside the converter.
- Check the holes on the Ring. If the holes are worn, perform item Reference. If the holes are in good condition, perform item Reference.
- Use a drilling machine with a drill the same size as the holes to drill the worn holes.

- Converter
- Ring
Risk of damage to the equipment.Always use penetrating lubricant on the threads. Both the
Ring and the
Converter are made of stainless steel and can easily seize.
- Use penetrating lubricant between the Converter and the Ring.
- Fit the Tool into the holes on the Ring.
- Place a 1/2 inch wrench in the Square hole of the Tool. Loosen the Ring.Note: Make sure not to turn the Shaft. Turning the Shaft can damage the wires inside the converter.

- Ring
- Tool
- Shaft
- Cable gland
- Square hole
- The Converter has a Range marker.
- The Shaft has an Arrow.
- Make sure that the Arrow on the Shaft is always inside the area marked by the Range marker. If the arrow point outside of the marked area, the wires inside the converter will be damaged.

- Converter
- Shaft
- Range marker
- Arrow
- The Arrow must never point to, or cross, the Forbidden area.

- Arrow
- Forbidden area
- Turn the Sonotrode 180 degrees.

- Sonotrode
- Install the Folding plate and the Bolt.

- Bolt
- Folding plate
- Make sure that the Sonotrode is parallel to the Folding plate by comparing distance A to distance B.Note: The distance between the Folding plate and the Sonotrode can not be changed. The only important setting is that the distances A and B are the same.

A = B ± 0.4 mm
- Folding plate
- Sonotrode
- Use an adjustable wrench to hold the Sonotrode in place. Make sure the Sonotrode is still parallel with the Folding plate. Set a 1/2" torque wrench to 220Nm and use the Tool to tighten the ring.

- Folding plate
- Tool
- Sonotrode
- Install the converter in the machine.
- Set the Sonotrode and the anvil. See Procedure Sonotrode and Anvil - Set (Align).
- Set the folding plate. See Procedure Folding Plate - Set.
Filters - Check
| Equipment Status | Power must be turn ON. Air must be turn ON. Steam must be turn ON. Water must be turn ON.
|
- Check the Particle filter. If the Particle filter is clogged, it must be replaced.
- Check the Adsorbent filter. If the Adsorbent filter has turned pink, it must be replaced.Note: If the filter has turned pink, it has reached its maximum adsorbent capacity.
- Make sure that the arrows on the filters point in the direction of the air flow.
- Make sure that the filters are installed in the right order, counting from the Pressure regulator, first the Particle filter, then the Adsorbent filter.

- Particle filter
- Adsorbent filter
- Pressure regulator
Folding Support Anvil and Lift - Check
| Equipment Status | |
| Special Equipment | Template TP No. 2633209-0101 |
- The three surfaces (A) are to be in line with each other. If not, proceed according to Folding Support Anvil and Lift - Set, item a).
- Check that the two surfaces (B) are parallel to each other. If not, proceed according to Folding Support Anvil and Lift - Set, items b) and c).
Folding Plate - Set
| Equipment Status | Program Step |
Note: The should be performed before this operation.- Set up the template according to illustration A
- Use the 0.5mm thickness gauge for Midi, Mini, and Micro.
- Use the 0.3mm +1.0 mm thickness gauge for Base.
- Put the template on the folding support in the machine, illustration B.
- Make sure that the machine is in zero position, and that the sealing jaws are open
- Step the machine up to air on.

Top: Illustration ABottom: Illustration B
- Pressurize the air cylinder to a minimum of 2 bar with the Regulator.
- Move down the linear yoke to mechanical stop, illustration C.
- Loosen the Folding plate screw and tighten them again by hand.
- Press the folding plate to set the gap B, illustration D, while again tightening the Folding plate screw.Gap B:Midi, Mini, Micro = 0.5 mmBase = 1.3 mm

Top right: Illustration CLeft: Illustration D
- Regulator
- Folding plate screw
Folding Support Anvil and Lift - Set
| Equipment Status | Program Step |
| Special Equipment | Bottom sealing template TP No. 2633209-0101 |
- Align (A) the outer Folding support to the template by means of the Screw.
- Loosen the eight Screw.
- Raise the cassette lifter by the aid of a Claw wrench, and tighten the screws again when alignment is reached between template and anvil.

- Screw
- Claw wrench
- Screw
- Folding support
Set distance A
- Loosen the Screw and tighten them again by hand.
- Loosen the Lock nut; turn the Screw clockwise to increase gap A; counter-clockwise to decrease the distance A.
- Tighten the Lock nut and the Screw.
- Again, check the distance A.
Bottom Sealing Unit - Remove
| Equipment Status | Program Step STEP ZERO |
| Special Equipment | Rail TP No. 915399-0201 Yoke TP No. 1025049-0001 Tackle block TP No. 90039-19 |
Risk of personal injury.Handle the bottom sealing unit with care and make sure that you take precautions to handle the weight.The bottom sealing unit is heavy and can cause personal injuries.
Risk of equipment damage.Handle the bottom seal unit with care and make sure that you take precautions to handle the weight.The bottom seal unit is heavy and can damage the equipment.
- Remove the Cover.
- Remove the four Nut.

- Cover
- Nut
- Push the Rail onto the Pin in the machine frame.
- Secure the Rail with the Screw.
- Secure the Rail by fitting the safety Rod and the Nut.

- Rail
- Pin
- Screw
- Rod
- Nut
- Remove the Screw and the Draining pipe.
- Disconnect the servo cable, the sonotrode cables, the oil hose, and the pneumatic hoses at both the inner and the outer side of the unit.
- If the machine has a gas dosing unit, disconnect it according to Procedure Bottom Sealing Unit - Remove Gas Dosing System Connections (Optional Equipment).

- Screw
- Draining pipe
- Loosen the Tie rod bracket and turn it upwards according to the illustration. Save the shims and note their position for assembling.
- Remove the Anvil.
- Push in the tie rods and the sonotrodes to mechanical stop.

- Tie rod bracket
- Anvil
- Loosen the Steering guide/Flap guide, the Bracket, and the Valve.
- Loosen the Securing plate/Holder and the Screw.
- Pull out the bottom seal. Make sure that no hose is squeezed or damaged.


- Steering guide/Flap guide
- Bracket
- Valve
- Securing plate/Holder
- Screw
- Go upstairs to the filling section.
- Remove the Plate.Note: Make sure that the Plate is siliconed to the frame when it is assembled to prevent any leakage through the plate.

- Plate
- Carefully secure the Yoke on top of the frame of the filling section with the Screw.
- Carefully secure the Tackle block to the Yoke.

- Yoke
- Screw
- Tackle block
- Secure the Lifting block hook to the Lifting eye bolt.
- Make sure that the weight of the bottom seal is fully transmitted to the Lifting block hook.
- Remove the front Roller bracket.

- Lifting block hook
- Lifting eye bolt
- Roller bracket
- Start lowering the bottom seal and push it forward to unhook the rear Roller bracket from the rail.

- Roller bracket
- Lower the bottom seal onto a Pallet on the floor.
- Assemble in the reverse order.

- Pallet
Bottom Sealing Unit - Overhaul
| Equipment Status | Program Step Step Zero |
| Special Equipment | Rail TP No. 915399-0201 Yoke TP No. 1025049-0001 Tackle block TP No. 90039-19 2595594 |
| Consumables | Thread locker TP No. 344431-0000 |
Dismantle
- Remove the Motor including the Upper coupling half.
- Remove the Lower coupling half.
- Hold the Ball screw tight using a 10mm key, and loosen the Nut.
- Remove the Screw and the Servo drive house.

- Motor
- Upper coupling half
- Lower coupling half
- Ball screw
- Nut
- Screw
- Servo drive house
- Remove the Sonotrode unit , and the Tie bar, and remove the Lubrication plate.Note: The Sonotrode unit are possible to pull out with the cable gland and pin plug still attached.
- Remove the Screw and lift out the whole Link system from the bottom sealing frame.Note: Let the Shim remain in their positions during the overhaul or note the position of the Shim.

- Sonotrode unit
- Tie bar
- Lubrication plate
- Screw
- Link system
- Shim
Disassemble Link System
Disassembled the Link system. See illustrations on the following pages.Note: Save the Shim for the assembly.Change Ball Screw
- Remove the Ball screw from the Carriage.
- Move the Lubrication inlet , the Screw, and the Washer to the new Ball screw.
- Apply thread locker to the Screw.
- Turn the Ball screw to the left until it reaches mechanical stop by the Washer.

- Ball screw
- Link system
- Shim
- Carriage
- Lubrication inlet
- Screw
- Washer
Change Linear Ball-Bushing Unit
- Change the internal parts in the Linear ball bushing unit.Note: The Reference surface must be pointing outwards from the Link system .

- Link system
- Linear ball bushing unit
- Reference surface
Change Linear Ball Bushings
- Change all the ball bushings on the Carriage, Carriage. Remove all internal seals (marked X) from the ball bushings.
- Change all the ball bushings and Seal ring on the Carriage, and Carriage.Remove all internal seals (marked X) from the ball bushings.Put the Seal ring with the black surface facing outwards.

- Carriage
- Carriage
- Carriage
- Carriage
- Seal ring
Change Linkage Ball Bearing and Ball Rail Unit
- Change the Linkage ball bearing according to Procedure Link Bearings - Change.
- Change the Ball rail unit according to Procedure Ball Rail Unit - Change.

- Linkage ball bearing
- Ball rail unit
Change Ball Screw Bearing
- Change the Bearing and put back the Plate according to the illustration.

- Bearing
- Plate
Check Pneumatic Membrane
- Pressurize the membrane with 5 bar and check for leakage.

- membrane
Assemble
Assemble according to Procedure Bottom Sealing Unit - Assemble.Bottom Sealing Unit - Assemble
| Equipment Status | Program Step Step Zero |
| Special Equipment | Centering Template TP No. 3002666-0000 |
| Consumables | Thread locker TP No. 344431-0000 Alcoholic solution (Isopropanol 70%) |
- Lift the link system into the bottom sealing housing.Note: Make sure that the Shims are in the correct position. From machine 63202/20111, the measurement of the shims is stamped to the frame.
- Check with a 0.05 mm feeler gauge that the reference surface of the Linear bearings is bearing against the Machined surface.
- Tighten the screws for the Linear bearings and the Carriages loose by hand.Note: Repeat item b).
- Push the Centering template into position in the groove of the housing.
- Assemble the Anvil.
- With the Centering template in position, tighten the screws for the Linear bearings and the Carriages.
- Tighten the other linear bearing (at the opposite side of the unit).
- Remove the Anvil and the Centering template.
- Assemble the houses with the O-ring and seal.
- Assemble the Anvil.

- Shims
- Linear bearings
- Machined surface
- Centering template
- Anvil
- Carriages
- O-ring and seal
- Put back the Lubrication plate and connect the hoses.
- Tighten the Screw.
- Tighten the Screw
- Fit new seals, see Procedure Seals - Change.

- Lubrication plate
- Screw
- Screw
- Make sure that the Link system can easily be moved up and down by hand.
- Apply thread locker to the Nut.
- Hold the Ball screw tight using a 10mm key, and tighten the Nut.
- Tighten four Screw for the Bearing house under the Frame.
- Make sure that the Link system can easily be moved up and down by hand.
- Wipe the Coupling halves and the shafts of the Ball screw and of the Servo motor with alcoholic solution.
- Fit the Coupling halves on the shaft of the Ball screw, and assemble the Servo motor. The connections for the Servo motor must be turned outwards.
- Check that there is a small gap between the Coupling halves, and tighten the coupling to 8 Nm.
- Make sure that the Link system can easily be moved up and down by hand.

- Link system
- Nut
- Ball screw
- Screw
- Bearing house
- Frame
- Coupling halves
- Servo motor
- Assemble the sonotrodes.
- Set the sonotrodes and the anvil. See Sonotrode and Anvil - Set (Align).
Bottom Sealing Unit - Fit
| Equipment Status | Program Step |
| Special Equipment | Rail TP No. 915399-0201 Yoke TP No. 1025049-0001 Tackle block TP No. 90039-19 |
Heavy equipment.Handle the bottom sealing unit with care and make sure that you take precautions to handle the weight.The bottom sealing unit is heavy and can cause personal injuries and damage to equipment.
- Remove the anvil (10), turn up the tie rod bracket (17), and remove the draining pipe (16).Note: Save the shims (23) and note their position for the assembling.
- Push in the tie rods and the sonotrodes to mechanical stop.
- If removed, fit the rails, yoke, and tackle block, in accordance with previous instruction Bottom Sealing Unit - Remove.
- Lift the bottom sealing unit onto the rails and fit the two removed roller brackets (12) into the rails track.
- Tighten the rollers, and push the unit into the machine. Make sure no hoses are squeezed or damaged.
- Secure the bottom sealing unit by the securing plate (11) and screws (19).
- Remove the yoke and tackle block.
- Tighten the steering guide (21), screws (20), and the valve (22).
- Turn down and tighten the bracket (17) to the tie rods.
- Use the saved shims (23), and fit the anvil (10).
- Fit the two servo cables, two sonotrode cables, oil hose, and pneumatic hoses.
- Fit the screws (15) to the hygienic chamber, and the draining pipe (16).
- Remove the rails.
- Align the sonotrodes, see Procedure Sonotrode and Anvil - Set (Align).
- Fit and tighten the nuts (14).
- Fit the cover (13).
- If the machine has a gas dosing system installed, connect it according to Bottom Sealing Unit - Fit Gas Dosing System Connections (Optional Equipment).
Lower Cassette Lift - Set
| Equipment Status | Program Step |
- Insert one of the Screw M8 x 50 mm in the lower hole of the rods.
- Loosen the Screw and check that the both Screw are resting against the top ring of the column.
- Tighten the Screw.

- Screw
- Screw
Lower Cassette Lift - Overhaul
| Equipment Status | Program Step |
- Remove the O-ring and Seal, Ball bushing, Rubber ring, and the O-ring, see illustration next page.Note: Be careful not to damage the cylinder housing when removing the Ball bushing, see illustration next page.
- Make sure that there is no blockage in the Oil channel. Use an airgun to do this.
- At reassembling, the Ball bushing are to be mounted so that the seal ring of the upper bushing is turned downward, and the seal ring of the lower bushing is turned downward (turned outwards from the column).
Risk of damage to the equipment.Use blunt tools and be careful when installing the
Seal.Sharp tools can damage the
Seal and cause leaks.
Fit the Seal in the Ring according to the illustration. Squeeze the seals by hand to make them enter the grooves in the lid. Then push the seals to the correct position by the aid of a suitable pen or similar.- At reassembling, check that the Oil channel in the column matches the Oil channel in the flange.
- Set according to Lower Cassette Lift - Set.

- Pillar
- Ball bushing
- Ring
- Oil channel
- Oil channel
- O-ring
- Seal
- Rubber ring
- O-ring
Upper Volume Displacers - Check
| Equipment Status | Program Step STEP ZERO |
Risk of crushing.Be careful when working near the moving parts.The machine contains moving parts that can crush.
- Check the Button and Button for damage.If necessary, change the buttons.
- Check for air leakage at the Cylinder, by the pistons and the push-in fittings. On Festo machines, use the air service tool. See Air Service Tool Description.If necessary, overhaul the cylinder. See Procedure Upper Volume Displacers - Overhaul.

- Button
- Button
- Cylinder
Upper Volume Displacers - Check
| Equipment Status | Program Step STEP ZERO |
Risk of crushing. Be careful when working near the moving parts.The machine contains moving parts that can crush.
- Check the Bow for damage. If necessary, change the bows.
- Make sure that the Bow are positioned vertically.
- Check for air leakage at the Cylinder, by the pistons and the push-in fittings.If necessary, overhaul the cylinder. See Procedure Upper Volume Displacers - Overhaul.

- Bow
- Cylinder
Upper Volume Displacers - Set
| Equipment Status | Program Step AIR ON |
Risk of crushing. Be careful when working near the moving parts.The machine contains moving parts that can crush.
- Inch the machine to an index position between sector value 300 and 800.
- Step the machine down to step zero.
- For Base: Loosen the Adjustment screw and set the distance A between the Pressure device/button and the Cassette. Tighten the Adjustment screw.For Midi/Mini/Micro: When measuring the distances A and B: Use 2 feeler gauges to centre the Cassette, one on each side. Loosen the Nut, rotate the Pressure Device to set the distances A and B, tighten the Nut.
| Base | Midi | Mini STD 200/250ml | Mini STD 330ml | MiniV ml | Micro |
| A (mm) | 6.0 ±0.5 | 4.0 ±0.5 | 6.0 ±0.5 | 4.0 ±0.5 | 3.5 ±0.5 | 5.0 ±0.5 |
| B (mm) | Not adjustable | 4.0 ±0.5 | 6.0 ±0.5 | 4.0 ±0.5 | 3.5 ±0.5 | 5.0 ±0.5 |

- Adjustment screw
- Pressure device/button
- Cassette
- Nut
- Pressure Device
- Centre the volume displacers in the holes of the cassettes and align with the machine creases.
- Set the throttle valve so that the volume displacers move smoothly, but not “too slow”. (Basic setting for the throttle valve is 4 revolutions from bottom (closed) position.)
- To check the settings, press the buttons by the valves in the pneumatic units, with the machine in stop position.
- Inner displacement V63K1206 (S1) and V63K2206 (S2)
- Outer displacement V63K1207 (S1) and V63K2207 (S2)
- During production, check that no product splashes are caused by the volume displacers.
Upper Volume Displacers - Overhaul
| Equipment Status | Program Step STEP ZERO |
Overhaul Cylinder (TP No. 90600-4737)
Risk of crushing.Be careful when working near the moving parts.The machine contains moving parts that can crush.
- Disconnect the Pneumatic hose.
- Remove the Screw.
- Remove the Cylinder from the machine and put it on a clean working area.

- Pneumatic hose
- Screw
- Cylinder
- Remove the Push-in fitting, the Screw, and the Button from the Cylinder.
- Assemble in the reverse order with a new Cylinder.If necessary, change the Push-in fitting and the Button.

- Cylinder
- Push-in fitting
- Screw
- Button
- Set the distance between the cassettes and the buttons. See Procedure Upper Volume Displacers - Set on page Upper Volume Displacers - Set.
- Make sure that the cylinders move smoothly and that no air is leaking from the pneumatic hose connections.Note: If there is a leakage, check if the pneumatic hoses are damaged. If necessary, cut them.
Overhaul Cylinder (TP No. 90602-9869)
Risk of crushing.Be careful when working near the moving parts.The machine contains moving parts that can crush.
- Disconnect the Pneumatic hose.
- Remove the Screw
- Remove the Cylinder from the machine and put it on a clean working area.

- Pneumatic hose
- Screw
- Cylinder
- Remove the Push-in fitting, the Screw, and the Button from the Cylinder.
- Assemble in the reverse order with a new Cylinder.If necessary, change the Push-in fitting and the Button.

- Cylinder
- Push-in fitting
- Screw
- Button
- Set the distance between the cassettes and the buttons. See Procedure Upper Volume Displacers - Set on page Upper Volume Displacers - Set.
- Make sure that the cylinders move smoothly and that no air is leaking from the pneumatic hose connections.Note: If there is a leakage, check if the pneumatic hoses are damaged. If necessary, cut them.
Upper Volume Displacers - Overhaul
| Equipment Status | Program Step STEP ZERO |
Risk of crushing. Be careful when working near the moving parts.The machine contains moving parts that can crush.
- Disconnect the Pneumatic hose.
- Remove the Screw.
- Remove the Cylinder from the machine and put it on a clean working area.

- Pneumatic hose
- Screw
- Cylinder
- Remove the Push-in fitting.
- Loosen the Hexagon nut and remove the Bow/Pressure device.
- Assemble in the reverse order with a new Cylinder.If necessary, change the Push-in fitting and the Bow/Pressure device.

- Cylinder
- Push-in fitting
- Hexagon nut
- Bow/Pressure device
- Set the distance between the bows and the cassettes. See Procedure Upper Volume Displacers - Set.
- Make sure that the cylinder moves smoothly and that no air is leaking from the pneumatic hose connections.Note: If there is a leakage, check if the pneumatic hoses are damaged. If necessary, cut them.
Cassette Lifter, Centring
Cassette Lifter, Centring - Set Height and Centring
| Equipment Status | Program Step |
- Inch the machine to a sector value between 300 and 800
- On Mecman machines, force the valves G50K1220 (S1), and G50K2220 (S2). On Festo machines, use the air service tool. See Air Service Tool Description.
- Adjust the height of the centred cassette by loosening the Lock nut and turning the Piston. Adjust so that the cassette is just touching the Rail, then turn the piston half a revolution more (to increase the contact pressure). Tighten the Lock nut.
- Run some packages through the machine, and check if the transversal seal lines up.
- If the transversal seal is unaligned in the way that illustration A shows, adjust the seal by loosening the Screw and moving the Centring in the direction of arrow A.
- If the transversal seal is unaligned in the way that illustration B shows, adjust the seal by loosening the Screw and moving the Centring in the direction of arrow B.

- Lock nut
- Piston
- Rail
- Screw
- Centring
After the centring procedure:- On Mecman machines, force the valves G50K1220 (S1), and G50K2220 (S2). On Festo machines, use the air service tool. See Air Service Tool Description.
- Check that there is a gap X, in the conveyor, on both sides of the entered cassette. If there is no gap, adjust using shims (see itemsReference to Reference).
- Loosen the Rear yoke, and adjust it with 1 mm shims (TP No 2673458) between the Tie rods and the Rear yoke.
- Tighten the rear yoke.
- Set the anvil and sonotrodes according to Procedure Sonotrode and Anvil - Set (Align).

- Rear yoke
- Tie rods
Cassette Lifter, Centring - Remove
| Equipment Status | Program Step |
- Remove the centring unit by removing the Screw.
- Remove the rest of the cassette lift unit by removing the Screw.Note: It is recommended to remove the cassette lift unit in the two pieces, as shown below, to keep the pre-settings.

- Screw
- Screw
Cassette Lifter, Centring - Assemble
| Special Equipment | Feeler gauge 0.05mm |
Note: Perform the assembly on a flat surface.- Assemble the Bracket and the Cantilever.
- Check that the Surface is parallel with the flat surface on which the assembly takes place.
- Assemble the Bracket to the Bracket.Note: The Bracket should rest against the Cantilever.

- Screw
- Washer
- Screw
- Washer
- Bracket
- Bracket
- Cantilever
- Surface
- Check the distance A with a 0.05mmfeeler gauge.

A = 0.05 mm
- Bracket
- Cantilever
- Assemble the Volume displacement to the Cantilever and the Bracket.Note: Do not tighten the Screw.

- Bracket
- Cantilever
- Screw
- Washer
- Volume displacement
- Parallel pin
- Screw
- Washer
- Place a Ruler on the Surface. Set the distance B and tighten the Screw.
- Check the angle between the Rail and the Bracket. The angle C should be 90° with the tolerance 0.2°.
- Check the distance D.
| D (mm) |
| Base | 71.0 ±0.5 |
| Midi | 56.2 ±0.5 |
| Mini | 49.0 ±0.5 |
| Micro | 36.0 ±0.5 |

B = 0 ±0.1 mm
C = 90° ±0,2 °
- Bracket
- Surface
- Ruler
- Rail
Basic Settings Bottom Seal
Cells containing hyphen (-) refers to a setting when the configuration exists, but no value is set.Cells with grey background refer to a setting in which the configuration does not exist.Italic text refers to a setting that has not been verified, but are based on verified settings from similar configurations.Designations /ml, /ml-H, /ml-H+, /pbl, /jl, /jl MF, /aqk and /lk indicate different packaging material specifications.The letters T and P indicate settings for pulse time (ms) respectively for the pressure (bar).| Valid for: CLC/C Duplex board |
| Bottom format | Board stiffness (mN) | Pulse Time T (ms) and Pressure P (bar) |
| /ml | /ml-H | /ml-H+ | /pbl | /jl | /jl MF | /aqk | /lk | |
| T | P | T | P | T | P | T | P | T | P | T | P | T | P | T | P |
| Base | 475 | | | 130 | 4.2 | | | - | - | | | | | | | | |
| Base | 370 | 130 | 3.6 | - | - | | | 140 | 3.2 | | | | | | | | |
| Midi | 260 | 160 | 2.6 | - | - | 150 | 3.0 | 150 | 3.0 | 130 | 3.2 | | | 140 | 4.0 | | |
| Mini/MiniV | 260 | 130 | 2.8 | - | - | 150 | 3.0 | 150 | 3.0 | 140 | 3.0 | 140(1) | 2.8(1) | | | 150 | 3.4 |
| Micro | 150 | | | | | | | 120 | 3.2 | | | | | | | | |
| (1): 150 mN board stiffness |
|
| Valid for: CLC/C Bleached board |
| Bottom format | Board stiffness (mN) | Pulse Time T (ms) and Pressure P (bar) |
| /ml | /ml-H | /ml-H+ | /pbl | |
| T | P | T | P | T | P | T | P |
| Base | 475 | | | | | | | | |
| Base | 370 | 150 | 3.8 | - | - | | | - | - |
| Midi | 260 | | | 160 | 2.8 | 150 | 3.0 | 150 | 3.0 |
| Mini | 260 | | | 140 | 2.6 | 150 | 3.0 | 150 | 3.0 |
| Micro | 150 | | | | | | | 120 | 3.2 |
|
Sealing Pressure Regulators - Set
| Equipment Status | Air must be turn ON.
|
- To decrease sealing pressure, turn the hand wheel counter-clockwise. Note: When decreasing pressure, it is necessary to turn approximately 0.4 bar below the estimated value, and then up again to the value.
- To increase sealing pressure, turn the hand wheel clockwise.
- Basic setting: choose the same pressure reading for both Pressure regulators one pressure regulator for each subside of the machine).
- At production, fine tune each side after checking the sealing quality.Note: During manufacturing and assembling of converters and sonotrodes, there is always a difference in the amplitude movement of the unit. This means that the air pressure regulators for the sealing pressure may have to be set individually between the subunit to create the same energy so that a good sealing can be produced. The energy values can be shown on the TPOP monitoring window.

- Pressure regulators
Sealing Time - Set
- Set the TS sealing time at the TPOP according to the illustration.Note: The energy values can be shown on the TPOP monitoring window.
Protective Air Pressure Regulator and Pressure Sensor - Set
- Set the air Pressure sensor.Note: Pressure guard display has to be in Run mode. When pushing the Arrow up button you can see the settings for SP Switching pressure and HY Hysteresis.

- Pressure sensor
- Arrow up
- Edit button
- Arrow down
- Pressure regulator
- Push the Edit button repeatedly to walk through the setting windows and do the necessary changes with the Arrow up and Arrow down buttons. Changes will be saved when pushing Edit button for a new setting window. The display will go back to
Run mode after the last setting window. The following table describes the Pressure sensor menu.| Symbol | Setting | Description |
| Out A | Select | Switching Output A |
| _l¯ | Select | Threshold comparator |
| [SP] | 0.3 bar | Switching Pressure |
| [HY] | 0.0 bar | Hysteresis |
| [NO] | Select | Normally open contact |
The signal goes low when the pressure is below 0.3 bar.
- Set the Pressure regulator so that the Pressure sensor shows 0.6 bar.
- If the Pressure sensor shows less than 0.3 bar, check for leakage, and check the particle filter. See Filters - Check.
- If necessary, the pressure regulator can be adjusted up to max 0.7 bar to get a higher pressure on the system. this can be done if there is a small leakage or a clogged filter.
Functional Description
The function of the final folder unit is to fold the transversal seal, form it to flaps and seal them to the bottom of the package to make the package stand steadily.Flap Guide - Set
| Equipment Status | Program Step |
- The Folding plate is to be in its bottom position.
- Check the distance A between the bottom of the Cassette and top of the Folding plate.
| Base | Midi | Mini | Micro |
| Distance A (mm) | 232.0 ±0.5 | 232.0 ±0.5 | 228.0 ±0.5 | 228.0 ±0.5 |
- Check the distance B = 3.0 ±0.5 mm between the Folding plate and Steering.
- If necessary, loosen the Clamp screws to adjust.

- Cassette
- Folding plate
- Clamp screws
- Steering
Steering - Set
| Equipment Status | Program Step |
| Special Equipment | Template Base 500 ml, TP No. 1506569 Template Midi 500 ml, TP No. 1590562 Template Mini 500 ml, TP No. 1521727 Template Micro 500 ml, TP No. 2651657 Template Base 500 ml, TP No. 1116652 Template Midi 500 ml, TP No. 1502244 Template Mini 500 ml, TP No. 1477039 Template Micro 500 ml, TP No. 2651151 Bottom Plate Micro, TP No. 2651657 Setting Template, TP No. 3440370-0000 (MiniV) |
- Put a cassette in the guiding rails with Template (Base, Midi, Mini = red colour) in correct position (smallest volume position for Midi, Mini, and 500 ml for Base).

- Template (Base, Midi, Mini = red colour)
- Steering
- Screw
- Screw
- Screw
- Template
- Place Template in a cassette and centre the Steering using the Screw, Screw, and Screw.
- Inch the machine forward to check the distance L2 with a ruler.Note: The distance L2 to the Steering and the sideways centring of the guide can be set using the Template.

L2 = 240.0 ±0.5 mm
- Template
- Steering
Flap Heater - Check
| Equipment Status | Program Step |
Burn hazard.Allow the nozzles to cool down before starting any work on them.The flap sealing nozzles are very hot when in operation and can cause severe burns.
- Remove the Nozzle from the Flap heater. The Nozzle can be pulled off of the Flap heater by hand. If you can not pull the Nozzle off of the Flap heater, set the nozzle according to Flap Heater - Set Nozzle.
- Check the Nozzle for contamination.
- If necessary, clean the Nozzle with a wire brush.
- If necessary, clear the holes in the Nozzle with a suitable cleaning tool.
- Fit the Nozzle to the Flap heater.

- Nozzle
- Flap heater
Flap Heater - Set
| Equipment Status | Program Step |
| Special Equipment | Template Base 500 ml, TP No. 1116653 Template Midi 500 ml, TP No. 1502242 Template Mini 250 ml, TP No. 1309694 Template Micro 100 ml, TP No. 2651150 Template Base 500 ml, TP No. 1506569 Template Midi 500 ml, TP No. 1590562 Template Mini 250 ml, TP No. 1521727 Template Micro 100 ml, TP No. 2651657 Setting Template, TP No. 3440379-0000 (MiniV) |
Burn hazard.Allow the nozzles to cool down before starting any work on them.The flap sealing nozzles are hot when in operation and can cause severe burns.
- Choose a cassette in front of the bottom sealing unit.
- Push the Template fully down into the cassette.
- Inch the machine so that the cassette, with the template, is in line with the nozzle.
- Lift Template.
- Put the Template in position.

- Template
- Template
- Make sure that you can remove the Nozzle by pulling it away from the flap heater. If not, set the nozzle according to Flap Heater - Set Nozzle.
- Fit the Nozzle.
- Loosen the Screw and Screw.
- Position the Nozzle in the Template (in the middle of the cassette play).
- Make sure that the measurements A and B are correct.
- Tighten the Screw and Screw.
- Check the position of the Nozzle again.
- Check that the Guide pipe are correctly positioned against the Template. Adjust if necessary.

A = 9 mm
B = 0 mm
C = 0.2 mm
- Template
- Template
- Nozzle
- Screw
- Screw
- Guide pipe
- Screw
- Support cam
- Cassette link
- Loosen the two Screw.
- Fit the Support cam 0.2 mm from the Cassette link.Note: Use a 0.2-mm feeler gauge between the Support cam and the Cassette link.
- Tighten the two Screw.
- Check that the air pressure is:
- 250 ±5 kPa (2.5 ±0.5 bar) for Base
- 200 ±5 kPa (2.0 ±0.5 bar) for Midi/Mini/Micro
Flap Heater - Set Nozzle
| Equipment Status | Program Step |
Burn hazard.Allow the nozzles to cool down before starting any work on them.The flap sealing nozzles are very hot when in operation and can cause severe burns.
Note: The Screw ends in a Ball that fits into a Groove on the Nozzle. The Ball is pushed out by a spring and when the Screw is correctly set the nozzle can be pulled off of the Flap heater by hand.- Loosen the Nut.
- Loosen the Screw.
- Adjust the Screw until the Nozzle can be pulled off of the Flap heater by hand but will not fall off on its own.
- Lock the Screw by tightening the Nut.
- Make sure that the setting is still correct.

- Screw
- Ball
- Groove
- Nozzle
- Flap heater
- Nut
Flap Heater - Fit Thermocouple
| Equipment Status | Program Step |
Burn hazard.Allow the nozzles to cool down before starting any work on them.The flap sealing nozzles are very hot when in operation and can cause severe burns.
- On bench, set distance A, according to illustration,
- Tighten the Thermocouple.
- Fit the flap heater.
- Set the flap heater in accordance with Flap Heater - Set.

A = 25+0/-0.5
- Thermocouple
Basic Settings
| Basic settings |
| Flap sealing heat (⁰C) |
| 400 |
Squeezer - Set
| Equipment Status | Program Step STEP ZERO |
| Special Equipment | Base Template TP No.1572464 Midi Template TP No. 1572463 Mini Template TP No. 1572462 Micro Template TP No. 2651149 |
Note: For bottom format Mini there is a more accurate setting of the squeezer. See Procedure Squeezer - Set, Improved Method (Valid for Mini only).- Check the basic measurements of the squeezers, according to below illustration.
- Set the transport-wheel according to Cassette Assemble - Set.
- Inch the cassette to “finished indexed position”.

- Cut
- Short surface
- Raise the Arm to its top position.
- Set distance C by the Clamp Screws.
| Distance C (mm) |
| Base | 272 ±0.5 |
| Midi | 272 ±0.5 |
| Mini | 272 ±0.5 |
| Micro | 281 ±0.5 |
- Check the distance A between the Package guides. Check that the Squeezer is centred ±0.5 mm sideways to the Package guides. Adjust by the Screws.
- Eliminate the cassette play by pushing (by hand) against the front side of the cassette (arrow), and, at the same time, set according to next item.
- Push the Template against the rear side of the cassette, and push the Squeezer against the template. Adjust by the Screws.

- Clamp Screws
- Screws
- Squeezer
- Package guides
- Template
- Arm
Drive Unit - Check
| Equipment Status | Program Step STEP ZERO |
- Check the Seal ring and Flange bearing for damage.
- Check the Link head for wear.
- Check the cylinders for leakage.

- Seal ring
- Flange bearing
- Link head
Drive Unit - Lubricate
| Equipment Status | Program Step STEP ZERO |
| Consumables | Grease: TP No. 344407-0000 |
- Lubricate through the four grease nipples (arrows in illustration).Note: Remove surplus lubrication.

- Seal ring
- Flange bearing
- Link head
Drive Unit - Overhaul
| Equipment Status | Program Step STEP ZERO |
| Consumables | Grease TP No. 344407-0000 |
- Pull out the Shaft and change the Flange bearing assemble.
- Change the Seal ring
- Change the Link head.
- Change the Cylinder.

- Seal ring
- Flange bearing assemble
- Shaft
- Cylinder
- Link head
Drive Shafts and Arms, Centring - Check
| Equipment Status | Program Step |
- Check that distances L1 = L2 ±1 mm. To adjust, loosen the Clamp screw.
- Check that the Arm allow the cylinders to work vertically.

- Clamp screw
- Arm
Functional Description
The function of the discharger unit is to pull the packages from the cassettes and place them on the conveyor chain. Packages with unsealed flaps are detected by a photocell (in the machine body), and ejected away.Discharger, Guiding Plate, Gripping Device
Overview

- Discharger
- Guide plate
- Gripping device
Gripping Device - Check Linear Bearing
| Equipment Status | Program Step |
- Check the condition of the Linear bearing.

- Linear bearing
Gripping Device, Level of Gripper fingers- Check
| Equipment Status | Program Step |
Check that the upper surfaces of the Gripper finger and the Shaft are level.
- Gripper finger
- Shaft
Gripper Fingers, Height - Check
| Equipment Status | Program Step |
Risk of crushing.Be careful when working near the moving parts.There are moving parts in the machine.
- The Gripper finger are to be fitted so that the upper surface of the gripper fingers level with the top surface of the Shaft.

- Gripper finger
- Shaft
- Bottom plate
- Cassette
Additional check
- Inch to lowest position of grippers, the distance between the upper surface of the Gripper finger and the Bottom plate, should be C = 18 +1/-0 mm.
- Inch to highest position of grippers, the gap between the Cassette and the Gripper finger, should now be D = 1.5-3.0 mm.

- Gripper finger
- Shaft
- Bottom plate
- Cassette
Grippers Fingers - Set
| Equipment Status | Program Step |
| Special Equipment | Base Template 1116653 Midi Template 1502242 Mini Template 1309694 Micro Template 2651150 |
Risk of crushing.Be careful when working near the moving parts.There are moving parts in the machine.
- Put the Template into the cassette.
- Adjust the Gripper finger, so that the they are in close contact with the machined surfaces of the template. Tighten the Screw.
- Remove the Template.

- Gripper finger
- Shaft
- Screw
- Template
- With the gripper fingers in squeeze position A, loosen the Screw and set the distances E equal, between the Pusher blade and the Gripper finger.
- Tighten the Screw.

- Gripper finger
- Shaft
- Pusher blade
- Screw
Discharger, Guiding Plate, Gripping Device - Change
| Equipment Status | Program Step |
- Remove the foot step and beam in front of the cam module.
- Remove the pusher blades.
- Loosen the screws of the Gripper and remove them.
- Undo the Screw and remove the Guide plate.
- Remove the air and lubrication hoses.
- Undo the Screw and pull out the entire discharger.
- Remove the Yoke by pulling it away from the Carrier.
- Assemble in the reverse order.

- Gripper
- Guide plate
- Screw
- Carrier
- Rail
- Screw
- Yoke
Discharger - Change Link Heads
| Equipment Status | Program Step |
- Remove the Air cylinder.
- Remove the link Rod by removing the Screw and Screw.
- Change the link heads on the link Rod.
- Repeat item Reference to Reference on all the Rod.
- Assemble in the reverse order.

- Air cylinder
- Rod
- Screw
- Screw
Discharger - Overhaul
| Equipment Status | Program Step |
- Remove the Screw and change the Carriage. Tighten the screws.
- Remove the Air cylinder.
- Remove all the Link rod by removing the Screw and Screw. Then remove the Rod.

- Screw
- Carriage
- Air cylinder
- Link rod
- Screw
- Screw
- Rod
- Change the link heads of the Link rod.
- Change the Ball bushing.
- Push out the plastic tubes, while putting back the Rod. Tighten the Screw.
- Put back the Air cylinder and tighten the Screw and Screw .
- Continue the assemble in the reverse order.

- Air cylinder
- Link rod
- Screw
- Screw
- Rod
- Ball bushing
- Screw
Gripping Device - Overhaul
| Equipment Status | Program Step |
- Loosen the Screw and remove the Gripper fingers.
- Remove the Screw and remove the Cover plate.
- Remove the Hub by pushing it up from below.
- Remove and check the Seal for wear and damage. Replace if necessary.
- Remove and check the Bushing for wear and damage. Replace them if necessary.
- Remove and check the O-ring for wear and damage. Replace them if necessary.
- Reinstall in the reverse order.

- Screw
- Gripper fingers
- Screw
- Cover plate
- Hub
- Seal
- Bushing
- O-ring
Discharger - Assemble
| Equipment Status | Program Step STEP ZERO |
| Consumables | Grease: TP No. 344407-0000 Thread locker: TP No. 351532-0000 |
- Install the Rail and the Carriage on the Cantilever. The Marking line of the Rail must align with the (machined surface) Reference surface and Reference surface of the Carriage .
- Make sure that the distances A and B are correct according to the illustration below.

A (mm) < 0.05
B (mm) < 0.05
- Rail
- Carriage
- Cantilever
- Marking line
- Reference surface
- Reference surface
- Sealing ring
- Lubricate the Sealing ring.
- Install the following parts in the Housing:

- Sealing ring
- Housing
- Upper ball bearing
- Lower ball bearing
- Plate
- Plate
- Insert the Shaft into the Housing.
- Screw the nuts onto the Shaft. The nuts fit next to the Lower ball bearing.
- Install the Link rod. Use thread locker on the threads of the bolts.
- Set the distance C between the centre points of the link heads.
- Apply thread locker to the threads of the Pin screw.
- Screw the Pin screw into the Rod.
- Apply thread locker to the protruding part of the Pin screw.
- Insert the Pin screw into the Air cylinder. Screw it fully home, but make sure it has threads enough for the lock nut.
- Lock the Pin screw with the lock nut.
- Fit the air cylinder to the housing.
- Screw the Pin screw fully into the shaft and tighten the second lock nut.

C (mm) = 65.0 +0/-1
- Shaft
- Link rod
- Pin screw
- Rod
- Air cylinder
Discharger, Belt Attachment - Fit
| Equipment Status | Program Step |
- Move the Discharger to the correct position in accordance with the Belt; loosen the Screw and adjust. Make sure that the Cantilever bears against the Pin. Tighten the screws.
- Fit the intermediary Shaft. Allow the two servo lifts to rest in their lowest position, to level the shaft (check by measuring). Tighten the screws.
- Tighten the couplings of the shaft to 15 Nm.

- Belt
- Belt attachment
- Discharger
- Screw
- Cantilever
- Pin
- Shaft
Discharger - Check Link Heads
| Equipment Status | Program Step |
- Check the link heads. Make sure there is no play in the Rod end. If there is excessive play, change the link heads. See Procedure Discharger - Change Link Heads.

- Rod end
Discharger - Clean Drain Plate
| Equipment Status | Program Step |
- Clean the Drain plate with paper towel. Make sure that the Outlets for the drain hoses are free.

- Drain plate
- Outlets
Ejecting Device - Check
| Equipment Status | Program Step |
Risk of crushing.Be careful when working near the moving parts.The machine contains moving parts that can crush.
Use the air service tool to perform the instructions in this procedure. See Section Air Service Tool Description.- Disconnect the Hose from the Pneumatic cylinder.
- Use compressed air to check the function of the of the ejecting device. Make sure that the ejecting device moves smoothly. If necessary, overhaul the ejecting device according to Procedure Ejecting Device - Overhaul.
- Assemble the Hose in the reverse order.
- Check for air leakage at the Pneumatic cylinder by the piston and the pipe couplings. If necessary, overhaul the cylinder according to Procedure Ejecting Device - Overhaul.

- Hose
- Pneumatic cylinder
- During hygiene chamber cleaning/disinfection, make sure that there is no liquid leakage from the hygiene chamber at the pneumatic cylinder. If necessary, change the O-rings according to the Procedure Ejecting Device - Change O-rings and Scraper Rings.
Ejecting Device - Set
| Equipment Status | Program Step HeatingProgram Step Pre-heating |
Risk of crushing.Do not set the ejecting device while the machine is running.There are moving parts in the machine.
- Set distance A or B between the Table and the lower support rail on the Stopper.
- Pressurize the cylinder and measure A or B.
- To adjust the Stopper, loosen the Nut.
- Adjust the Piston rod.
- Tighten the Nut.
- Set the distance D between the Table and the inner side of the Chain guide.
- Set the distance C between the straight edge of the Control plate to the lower support rail on the Stopper.
- Check the distance E. See Procedure Pusher - Set.Illustration and table with setting values on the next page.
-
| Base | Midi | Mini | Micro |
| A (mm) | 75.5 ±0.5 | 69.0 ±0.5 | 63.0 ±0.5 | 60.0 ±0.5 |
| B (mm) | 81.0 ±0.5 | 74.5 ±0.5 | 68.5 ±0.5 | 65.5 ±0.5 |
| C (mm) | Not adjustable | 60.0 ±0.5 | 50.0 ±0.5 | 38.0 ±0.5 |
| D (mm) | 77.0 ±0.5* | 77.0 ±0.5 | 77.0 ±0.5 | 77.0 ±0.5 |
| * To achieve the correct distance C. | |

Illustration shows the
Control plate for Midi, Mini, and Micro.
- Stopper
- Screw
- Control plate
- Table
- Piston rod
- Nut
- Chain guide
Ejecting Device / Head Guide - Set
| Equipment Status | Program Step |
- Set distance E = 5.0±0.5 mm, as illustrated, between the Head guide and the Stopper.

The illustration shows Base and Midi
- Head guide
- Stopper
Outfeed guide - Set
- Set the Outfeed guide in accordance with the table below:
| Base | Midi | Mini | Micro |
| Different design | End position right | F = 106 mm | End position left |

The illustration shows Micro
- Outfeed guide
- Bottom plate
Ejecting Device - Change O-rings and Scraper Rings
| Equipment Status | Program Step STEP ZERO |
- Disconnect the hoses from the Pneumatic cylinder.
- Remove the Screw and loosen the piston rod and remove the Stopper.
- Remove the Rod.
- Remove the Screw and the Washer.
- Remove the Screw and lift out the Bearing housing and the Pneumatic cylinder.

- Pneumatic cylinder
- Screw
- Stopper
- Rod
- Screw
- Washer
- Screw
- Bearing housing
- Change the three O-ring.
- Change the two Scraper ring.
- Assemble the ejecting device in the reverse order.

- O-ring
- Scraper ring
Ejector Device - Install Stopper
| Equipment Status | Program Step |
- Install the Stopper on the Rod with the Bracket and the Screw according to the illustration below.

- Stopper
- Rod
- Bracket
- Screw
Pusher - Check
| Equipment Status | Program Step |
Risk of crushing.Do not make adjustments while the machine is running.There are moving parts in the machine.
- Check the Pneumatic cylinder for leakage. On Festo machines, use the air service tool. See Air Service Tool Description.
- Check the condition of the Ball bushing, the Gasket, the scrapers inside the gaskets, and the Rod. Look for liquid below the rod, see arrow.Replace if necessary, see Procedure Pusher - Overhaul.
- Check if the Screw, the Screw, and the Screw are tight. Tighten if necessary.

- Pneumatic cylinder
- Screw
- Ball bushing
- Gasket
- Rod
- Screw
- Screw
Pusher - Change Prop. Valve
| Equipment Status | Program Step |
- Disconnect the pneumatic hoses.
- Disconnect the electric connection.
- Remove the Screw and the Prop. valve.
- Change the Prop. valve.
- Assemble in the reverse order.

- Screw
- Prop. valve
Shock Absorber - Set
| Equipment Status | Program Step step zero |
- Check that the piston rod of the cylinder is screwed fully home into the Movable bracket.
- Loosen the Nut and the Nut.
- Move the Pneumatic cylinder backward, as far as possible, against the Shock absorber. At the same time, push in the shock absorber as much as possible.
- Set the distance A between the pneumatic cylinder and plastic top of the shock absorber.
- Tighten the nuts.Note: With loosened Nut and Nut, insert a 3 mm feeler gauge between plastic top and pneumatic cylinder. Move the cylinder backward and push in the shock absorber. Tighten the nuts.

- Movable bracket
- Nut
- Nut
- Pneumatic cylinder
- Shock absorber
Pusher - Set
| Equipment Status | Program Step |
Risk of crushing. Adjustment must not be made when the machine is running.There are moving parts in the machine.
- Adjust the Stopper to its outmost position (pressure ON).
- Inch until the Pusher blade is in its outmost position.
- Adjust the Pusher blade to distance A, according the chart below (between the edge of the pusher blade and the upper bar of the stopper plate).
- Make sure that the pusher blade is at right angles to the bottom plate. Adjust by the joint and the Screw .
| Variant | Base | Midi | Mini | Micro |
| Distance A | 81 ±0.5 mm | 66. 5±0.5 mm | 54 ±0.5 mm | 41 ±0.5 mm |

- Stopper
- Pusher blade
- Screw
- Set the vertically gap between the Guiding plate and the Pusher blade to distanceB . Adjust by rising or lowering the Guiding plate.

B (mm) = 0.2 to 1.0
- Guiding plate
- Pusher blade
Pusher - Remove
| Equipment Status | Program Step |
- Remove the Screw and remove the Pusher blade.
- Remove the Screw and remove the Flange.
- Remove the pneumatic hoses from the Cylinder.
- Remove the Screw and remove the pusher unit.
- Remove the Screw and lift out the Housing.

- Screw
- Pusher blade
- Screw
- Flange
- Cylinder
- Screw
- Screw
- Housing
Pusher - Overhaul
| Equipment Status | Program Step |
- Change the Seal ring and the Cylinder.

- Seal ring
- Cylinder
Proximity Switch Pusher - Set
Note: The Cylinder piston must be screwed fully home into its floating connection.- Set the distances A, from the proximity switches to the end movement positions of the pusher, by loosening the Nut and moving the proximity switches in their long holes.
- Set the height of the proximity switches so that the gap between proximity switch and pusher is according to distance B, by loosening the Nut .
- Tighten the nuts.

A (mm) = 2 - 3
B (mm) = 1 - 1.3
- Cylinder piston
- Nut
- Nut
Pusher - Check Shock Absorber
| Equipment Status | Program Step step zero |
- Check if the Shock absorber is not broken. Check if it moves freely and the white plastic tip is present. Change if necessary.

- Shock absorber
Pusher - Set Throttle Check Valve
| Equipment Status | Program Step HEATING |
- Remove the protective Plug.
- Insert a Screwdriver through the hole.
- Close the Throttle check valve completely with the Knob.
- Open the Throttle check valve with 6.5 turns. The Cylinder should move noiseless and with even movements.

- Plug
- Screwdriver
- Throttle check valve
- Knob
- Cylinder
Adjustments- Adjust the throttle check valves until the speed of the outfeed pushers are satisfactory.
- Backward movement:
- Adjust the throttle check valve until the outfeeder is fully in backward position, before the discharger downward movement starts.
- Forward movement:
- Adjust the throttle check valve to enable a smooth package transfer.Note: If the speed is too low, the alarm "Outfeed Pusher Overload" will appear. See .Note: If the speed is too low, packages can turn on the conveyor.
Conveyor Chain - Check Chain and Chain Guide
| Equipment Status | Program Step |
- Push the conveyor chain in the direction of the arrow in the illustration, with a force of 30 N. At the same time, measure the distance A. Do this within the grey-marked area.
- If the distance A is not correct, adjust it with the Nut.

A (mm) = 6 ±2
- Conveyor chain
- Chain guide
- Nut
- Check the Chain and the Chain guide for wear or damage.
- If worn of damaged, change the Chain and the Chain guide according to Procedure Conveyor Chain - Change.

- Chain
- Chain guide
Conveyor Chain - Set
| Equipment Status | Program Step |
- Set the distance A between the Chain guard and conveyor Chain guide. To set the distance A, use the Shim in the front end and the Nut at the rear end.

A (mm) = 30
- Chain guard
- Chain guide
- Shim
- Nut
- Set the vertical distance B between the Discharge conveyor chain and the Conveyor chain. Use the Shim and Shim.
- Set the Conveyor chain so that is parallel to the Discharge conveyor chain on the horizontal plane. Use the Shim on the underside of the Chain guard and/or the Shim and Shim under the brackets.

B (mm) = 1-2
- Shim
- Discharge conveyor chain
- Conveyor chain
- Shim
- Shim
- Set the distance C between the drive motor Gear wheel and the Conveyor chain. Use the Mounting bolt, and the Adjustment screw.
- Set the Counter roller at 15 degrees on the Setting scale. Set by means of the Mounting bolt.

C (mm) = 0-1
- Conveyor chain
- Shim
- Shim
- Gear wheel
- Mounting bolt
- Adjustment screw
- Counter roller
- Setting scale
- Mounting bolt
- Push the conveyor chain in the direction of the arrow in the illustration, with a force of 30 N. Then, use the Nut to set the distance D. This is done to set the conveyor chain tension. Do this within the grey-marked area.

D (mm) = 6 ±2
- Nut
Conveyor Chain - Change
| Equipment Status | Program Step |
- Undo the Nut.
- Lift the Conveyor chain up and knock the Pin out.
- Assemble in the reverse order.

- Nut
- Conveyor chain
- Pin
UV-lamp
Safety hazard.Read and follow the safety precautions carefully before starting any work on the UV-lamp.There are several safety hazards involved when working with the UV-lamp.
Functional Description
The UV-lamp system consists of two UV-lamp units and their cooling system (one on each side of machine side).The combination of peroxide and UV-radiation effectively disinfects the surface of the packaging material.In order to reduce heat, the UV-lamp is cooled by a Venting fan, which sucks air through the Lamp housing. 
- Venting fan
- Temperature sensor
- Lamp housing
The cooling capacity (speed of venting fan) is controlled by the Temperature sensor and a frequency converter. The optimal cooling air temperature is 55 °C. (The cooling temperature is permanently preset. It is not necessary to check or adjust it.)Illumination of the hygiene chamber by UV light:The UV light has an additional function Illumination by UV light, which can be used to illuminate the hygiene chamber for approximately 10 minutes. The UV lamp will be extinguished (goes immediately out) under alarm conditions or upon opening of a door.To prevent overheating of the package cassettes, the lamp will only work during the program steps MOTOR RUNNING, PRODUCTION, END PRODUCTION, and when the machine is performing a VOLUME CHANGE.
- UV lightIllumination by
UV Meter - Set Offset
To get a correct measurement of the UV-lamp intensity it is important that the offset of the sensor is correctly set. The offset needs to be set when a new sensor is used or if the intensity not is 0.00 mW/cm2. | Equipment Status | Power must be turn ON.
|
| Special Equipment | UV-meter TP No. 90459-3591 |
- Connect the sensor in channel 1 on the UV meter.
- Turn the UV meterLight inlet aperture.
If the value E on the UV-meter is anything other than 0.00, follow items Reference to Reference. If the value is 0.00, go to Procedure UV-lamp - Check Intensity
- ON
- Press the arrow down-button until the Marker is in front of adjust offset.
- Press the OK button.
- Cover the Sensor and press the OK button.

- arrow down-button
- Marker
- OK button
- Sensor
- When all four values (A1 to A4) are shown, the offset is done.
- Press the OK button.

- OK button
UV-lamp - Check Intensity
| Equipment Status | Program Step Tank filling |
| Special Equipment | UV-meter TP No. 90459-3591 UV-sensor holder Base/Mini TP No. 1590181 UV-sensor holder Midi/Micro TP No. 1590279 Lid for sensor holder TP No. 3002667 |
| Consumables | Alcoholic solution (Isopropanol 70%) |
Prepare UV-meter
The following equipment is required: UV-meter, Lid for UV-sensor holder, UV-sensor, and Sensor holder.- Make sure the UV-meter has fresh batteries; otherwise, the measurements will be incorrect. The UV-meter is to be calibrated once a year by the agency of the manufacturer.
- Make sure that the serial number of the UV-sensor is the same as the one on the UV-meter. The UV-sensor and UV-meter are calibrated together and must be used together.
- Clean the UV-sensor using a soft lint-free cloth and alcoholic solution (Isopropanol 70%). See Chemicals for Cleaning and Disinfection.

- UV-meter
- UV-sensor holderLid for
- UV-sensor
- Sensor holder
Activate With XH (only for variant XH)
- If you have an XH machine, make sure With XH (only valid for XH machines) is selected. If necessary to select, step up the machine to program step air on.

With (only valid for XH machines)
Prepare Machine
Burn hazard.Allow the UV-lamp and the surrounding parts to cool down before starting any work on them.The UV-lamp and the surrounding parts can be hot.
Incorrect valuesMake sure that the quartz glasses are clean and dry. Make sure that the reflector is clean.The quartz glasses must be clean and dry. The reflectors must be clean. Otherwise, the measured values may be incorrect.
- Check the quartz glasses. See Procedure UV Lamp - Check Quartz Glass.
- Check the reflectors. See Procedure UV-Lamp - Check Reflector Sheets.

- Quartz glasses
- Inch the machine to MSP (Main Shaft Position) 500 - 900.
- Open the doors, and put the Holder-sensor-lid unit in the Cassette, centred under the UV lamp.
Incorrect values.Before using the UV-meter, make sure that the
Cassette is straight by using a
Flathead screwdriver between the plastic links, according to illustration.If the
Cassette is not straight, the measured values can differ by up to 50% from the correct values.
- Start the UV-meter.
- Make sure that the UV meter offset is correct. See Procedure UV Meter - Set Offset.
- Close the doors.

- Cassette
- Flathead screwdriver
- Holder-sensor-lid unit
Measure UV-intensity
- Step up the machine to heating (for 1900 and 2000 machines) or Pre-heating on 1800 machines.
- Press Manoeuvre window and Package disinfection.

Manoeuvre windowPackage disinfection
- Press Settings.

Settings
- Select Settings.
- Press Turn on UV-lamp.

NoneTurn on
- Wait two minutes.
- Select Shutter .
- Select Open Shutter .Note: The shutter is open for 20seconds.

Open ShutterShutter
- Press Start/stop on the UV-meter and measure for 10seconds, then press Start/stop. A stopwatch starts when Start/stop is pushed.
- Press the Arrow down button until the frame shown displays.
- Read the value that is shown after /E (mean value).Note: The value is only visible for 15seconds. If the value disappears, repeat items to .

- UV-meter
- Start/stop
- Arrow down
- None
- If the UV-meter reads above A, the UV-intensity is approved. Continue to item Reference. If the UV-meter reads below A, perform items Reference to Reference.
| UV-meter | A |
| 90459-3591 | 65 (mW/cm2) |
| 70 (mW/cm2) (valid for calibration of UV-meter done before October 2020). |
- Change the UV lamp power output to 5kW on the TPOP.
- Do a new UV intensity check.
- If the intensity is still below A, change the UV lamp. See Procedure UV-lamp - Change.
- After the UV-lamp has been changed, reset the UV lamp power output to 4kW, and do a new UV intensity check.
- If the intensity of the new UV lamp is below 93 mW/cm2, follow Procedure 5.6.2.2 Troubleshooting.Note: 100 (mW/cm2) (valid for calibration of UV-meter done before October 2020).
- Remove all the equipment and tools from the machine.

- UV lamp power output
UV-lamp - Check End Plate O-ring
| Equipment Status | Power must be turn OFF.
|
Risk of damage to the equipment.Handle the internal armature with care.Collisions will cause premature failure of the UV-lamp.
- Remove the internal Armature from the UV-lamp housing according to Procedure Reference for the non USA/Canada variant or Procedure UV-lamp House - Remove the Internal Armature for the USA/Canada variant.
- Check the O-ring on the End plate for wear and damage.
- If worn or damaged, replace the O-ring according to item Reference.
- Stretch the new silicon O-ring slightly while fitting it in the notch.
- Fit the internal Armature from the UV-lamp housing according to Procedure UV-lamp House - Fit Internal Armature.

- O-ring
- End plate
UV-lamp Ballast Coils - Set Different Voltage
| Equipment Status | Power must be turn OFF.
|
Hazardous voltage. The circuits of the UV lamp can contain residual voltage even after the power is turned off. The electrical supply disconnecting device must be switched off and secured with a lock before starting any work in the electrical cabinet. Wait at least five minutes after turning the power off before you continue to work with the ballast coils.Will shock, burn, or cause death.
Risk of damage to the equipment.Set the
Ballast coil to 380v, according to the following procedure, if the machine is supplied with 380v.If the
Ballast coil are set for the standard 400v supply when the machine is supplied with 380v, the UV-lamp intensity will be too low.
- Set a voltage meter (or multimeter) to AC voltage and a range above 400V.
- Hold the test probes against terminal 2 and terminal 4 on the contactor to drain the capacitor.
| S1 | S2 |
| 1800 | K105 | K106 |
| 1900 | K105 | K106 |
| 2000 | V51Q1013 | V51Q2013 |
- Move the Cables from the 400v connection to the 380v connection.
- Repeat item a) on all six Ballast coil.

- Ballast coil
- Cables
- 400v connection
- 380v connection
UV-Lamp - Set Shutter
| Equipment Status | Power must be turn OFF.
|
| Special Equipment | Torque wrench |
| Consumables | Alcoholic solution (Isopropanol 70%) |
Note: Two persons are needed to perform this procedure.- Loosen the Screw and the two Screw on the shaft coupling.
- Loosen the screws that hold the Switch.
- Pull the Shutter to the side, and hold it there.
- Push the Block to the mechanical end position, and tighten the Screw.
- Pull the Shutter to the side, and hold it there.
- Tighten the two Screw to 2Nm. Be careful not to overtighten the Screw. Too much force can damage the screws.
- Use a 1mm feeler gauge to set the distance between the Switch and the Block. Tighten the screws to the Switch.
- Release the Shutter and the Shutter.Note: Make sure that the switch is correctly adjusted. The switch must be activated (click sound) when the shutters are fully opened.

- Shutter
- Screw
- Shutter
- Block
- Switch
- Screw
- Make sure that the Cogwheels align.
Correct
Incorrect- Cogwheels
- Make sure that the Slot is centred between the two Shaft.
- Use a soft lint-free cloth and alcoholic solution (Isopropanol 70%) to clean the Reflector sheet.

- Cogwheels
- Reflector sheet
- Shaft
- Slot
Throttle Check Valve - Basic SettingThe purpose of this instruction is to adjust the throttle check valves that regulate the opening and closing of the shutters.If the shutters open too slowly, an alarm will be activated.If the shutters close or open too quickly, the shutters will crash too hardly into the UV-lamp house.- Locate the Throttle valve and Throttle valve on top of the hygiene chamber
- Turn the valves clockwise until they are in the fully closed position.
- Turn the valves anti-clockwise 7 full turns.
- Check the opening of the shutters. If the shutters move too quickly or too slowly, use the valves to adjust the speed.

- Throttle valve
- Throttle valve
UV-lamp House - Remove the Internal Armature
| Equipment Status | Power must be turn OFF.
|
Burn hazard.Allow the UV-lamp and the surrounding parts to cool down before starting any work on them.The UV-lamp and the surrounding parts can be hot.
Hazardous voltage.The circuits of the UV-lamp can contain residual voltage even after the power is turned off. Make sure that the electrical supply disconnecting device is turned off and secured with a lock and that you do the correct short circuit procedure, before starting any work on the UV-lamp.Will shock, burn, or cause death.
- Set the electrical supply disconnecting device to O. Wait at least five minutes before you continue to work with the UV-lamp.
- Disconnect the Pneumatic hose from the UV-lamp.
- Disconnect the cables at the Quick connection.

- Pneumatic hose
- Quick connection
- Remove the eight Screw.
- Remove the three Bolt.
- Carefully remove the internal armature from the UV-lamp housing.

- Screw
- Bolt
UV-lamp - Change
| Equipment Status | Power must be turn OFF.
|
| Consumables | Alcoholic solution (Isopropanol 70%) |
- Remove the internal Armature from the UV-lamp housing according to Procedure Reference for the non USA/Canada variant or Procedure UV-lamp House - Remove the Internal Armature for the USA/Canada variant.
- Remove the four Cable.
- Loosen the Screw.
- Pull the Lamp support out.

- Cable
- Screw
- Lamp support
Hazardous substances.Handle and dispose of the UV-lamp in compliance with local regulations.The UV-lamp contains mercury that can be hazardous to your health.
Remove the UV-lamp.- Make sure that the Reflector sheet is clean and without any scratches. If necessary, clean it with a soft lint-free cloth and alcoholic solution (Isopropanol 70%). See Chemicals for Cleaning and Disinfection, or change it according to Procedure UV-lamp - Change Reflector.
Risk of damage to the equipment.Do not touch the UV-lamp or the quartz glasses with your bare hands.Stains made by touching the UV-lamp or the quartz glasses with your bare hands will burn into the glass and cause premature failure.
Remove any fingerprints and other contamination from the new UV-lamp with a soft lint-free cloth and alcoholic solution (Isopropanol 70%). See Chemicals for Cleaning and Disinfection.
- UV-lamp
- Reflector sheet
- Check the tightness of the six Screw securing the Ring to the UV-lamp house. See UV-lamp - Check Screws for Quartz Glass.

- Screw
- Ring
- Chemicals for Cleaning and DisinfectionMake sure that the Quartz glass are clean and without any scratches. If necessary, clean both sides with a soft lint-free cloth and alcoholic solution (Isopropanol 70%), see , or change them according to ProcedureUV-lamp - Change Quartz Glass.
- Assemble in the reverse order.
- Use the TPOP, menu Setting and Information Package disinfection S1 or S2, to set the UV-lamp input power to 4 kW.
- Check the functionality of the new lamp, and do a new UV-lamp intensity check, according to Procedure UV-lamp - Check Intensity.

- Quartz glass
UV-lamp - Change Reflector
| Equipment Status | Power must be turn OFF.
|
- Remove the internal armature from the UV-lamp housing according to ProcedureReference for the non USA/Canada variant or Procedure UV-lamp House - Remove the Internal Armature for the USA/Canada variant.
Hazardous substances.Handle and dispose of the UV-lamp according to local regulations.The UV-lamp contains mercury that can be hazardous to your health.
Risk of damage to the equipmentDo not touch the UV-lamp with your bare hands.Stains that are made by touching the UV-lamp with your bare hands burn into the glass and cause premature failure.

- Screw
- Support
- Metal plate
- If the Shutter is closed, open it by hand.
- Loosen the 22 Screw.
- Lift the Upper holder, and at the same time, remove the old Reflector sheet. Repeat for the other Reflector sheet.
Risk of damage to the equipment.Be careful when you work with and around the reflector sheets.The surface of the
Reflector sheet can easily be scratched or damaged.
Remove the protective plastic film from the new reflector sheets.- Put the lower part of the new Reflector sheet in theLower holder and under the Upper holder. Repeat for the other Reflector sheet.Note: The upper and lower parts of the reflector are not the same. Make sure that you put the lower part of the reflector sheet in theLower holder so that the curve of the reflector sheet matches that of the shutter.
- Tighten the 22 Screw.
- Clean the Reflector sheet with a clean soft, lint-free cloth and alcoholic solution (Isopropanol 70%. See Chemicals for Cleaning and Disinfection.
- Clean the UV-lamp with a clean soft, lint-free cloth and alcoholic solution (Isopropanol 70%). See Chemicals for Cleaning and Disinfection.
- Assemble in the reverse order.
- Fit the internal Armature from the UV-lamp housing according to Procedure Reference for the non USA/Canada variant or Procedure UV-lamp House - Remove the Internal Armature for the USA/Canada variant.

- Shutter
- Screw
- Upper holder
- Reflector sheet
- Lower holder
UV-lamp - Change Quartz Glass
| Equipment Status | Power must be turn OFF.
|
| Consumables | Alcoholic solution (Isopropanol 70%) |
- Remove the internal Armature from the UV-lamp housing according to ProcedureReference for the non USA/Canada variant or Procedure UV-lamp House - Remove the Internal Armature for the USA/Canada variant.
- Place one hand under the Quartz glass. Remove the six M4 Screw securing the Ring to the UV-lamp house.
- Remove the Ring, the O-ring, and the Quartz glass.

- Quartz glass
- Screw
- Ring
- O-ring
- Remove the two O-ring.
- Use a clean, soft lint-free cloth and alcoholic solution (Isopropanol 70%). See Chemicals for Cleaning and Disinfection, to clean the inner Notch.
Risk of damage to the equipment.Handle the teflon O-rings with care, and always use new teflon O-rings when you install the quartz glasses.The teflon O-rings are fragile and can easily be deformed.
Fit the two new O-ring.
- O-ring
- Notch
Risk of damage to the equipment.Do not touch the quartz glasses with your bare hands.Stains made by touching the quartz glasses with your bare hands will burn into the quartz glasses and cause premature failure.
Risk of damage to the equipment.Handle the quartz glass gaskets with care, and always use new quartz glass gaskets when you install the quartz glasses.The quartz glass gaskets are fragile and can easily be deformed.
Assemble the Ring, the Gasket and the Quartz glass, and the O-ring, according to the illustration. Replace the O-ring if worn or damaged. Fit the parts to the lamp house by crosswise tightening the Screw until they have been tightened to the mechanical stop.
- Screw
- Ring
- Gasket
- Quartz glass
- O-ring
- Use a soft lint-free cloth and alcoholic solution (Isopropanol 70%) to clean the quartz glasses. See Chemicals for Cleaning and Disinfection.
- Fit the internal armature from the UV-lamp housing according to Procedure UV-lamp House - Fit Internal Armature.
UV-lamp House - Fit Internal Armature
| Equipment Status | Power must be turn OFF.
|
Risk of damage to the equipment.Handle the internal armature with care.Collisions will cause premature failure of the UV-lamp.
- Put the internal armature in the UV-lamp house. Follow Procedure Reference for the non USA/Canada variant or Procedure UV-lamp House - Remove the Internal Armature for the USA/Canada variant in the reverse order.
- Check the position of the UV-lamp cables. The cables must not be twisted or turned. Correct the cables, if necessary.
UV-meter - Calibration
| Special Equipment | UV-meter TP No. 90459-3591 |
The UV-sensor together with the UV-meter are to be calibrated once a year through the agency of the manufacturer.The service technicians or laboratory personnel using the metering device are responsible for the calibration being carried out at the correct intervals.
- UV-meter
- UV-sensor
UV-Lamp - Service Illumination
| Equipment Status | Program Step |
The UV-lamp can be used for short times to illuminate the hygiene chamber during service or volume change.The UV-lamp will immediately shut down when an alarm occurs or if a safety door is opened.To prevent overheating, the UV-lamp can only be used for illumination for 10 minutes at a time and only in the following machine statuses: motor running, production, end production, and when the machine is performing a volume change.- Press Manoeuvre window.
- Press Package disinfection for the side of the machine to be illuminated.
- Press Illuminate by UV light.

Manoeuvre windowPackage disinfectionIlluminate by
UV-Lamp - Check Shutter
| Equipment Status | Power must be turn OFF.
|
- Put the Shutter into their fully opened position.
- If the shutters do not reach a mechanical stop against the insert, set them according to Procedure UV-Lamp - Set Shutter.

- Shutter
UV Lamp - Check Quartz Glass
| Equipment Status | Power must be turn OFF.
|
| Consumables | Alcoholic solution (Isopropanol 70%) |
Burn hazard.Allow the UV-lamp and the surrounding parts to cool down before starting any work on them.The UV-lamp and the surrounding parts can be hot.
- Check that the Quartz glass are clean on the inside and have no scratches or other damage.
- If necessary, clean the Quartz glass with a soft lint-free cloth and alcoholic solution (Isopropanol 70%). See Chemicals for Cleaning and Disinfection, or replace the quartz glasses. See Procedure UV-lamp - Change Quartz Glass.

- Quartz glass
UV-Lamp - Check Reflector Sheets
| Equipment Status | Power must be turn OFF.
|
| Consumables | Alcoholic solution (Isopropanol 70%) |
Burn hazard.Allow the UV-lamp and the surrounding parts to cool down before starting any work on them.The UV-lamp and the surrounding parts can be hot.
- Check the Reflector sheet inside the UV-lamp housing to see if they are damaged or matted.
- If necessary, clean the Reflector sheet with a soft lint-free cloth and alcoholic solution (Isopropanol 70%). See Section Chemicals for Cleaning and Disinfection.
- If necessary, change the Reflector sheet according to Procedure UV-lamp - Change Reflector.

- Reflector sheet
UV-Lamp - Check Incoming Voltage
| Equipment Status | Power must be turn ON.
|
| Special Equipment | Digital Multimeter with True RMS (TRMS) |
- In the electrical cabinet, measure the incoming 400VAC on the Circuit breaker, between terminal 1 and 3.The incoming voltage to the machine should be 400 V or higher on all three phases.
- If the incoming voltage is too low, continue fault finding according to Section Troubleshooting - UV-Lamp Intensity.

- Circuit breaker
UV-Lamp - Check Power
| Equipment Status | Program Step HEATING |
| Special Equipment | Digital Multimeter with True RMS (TRMS) Digital Current Clamp Meter with True RMS (TRMS) |
- Make sure that the UV-lamp is on and that the shutter is open. See UV-lamp - Check Intensity. Check items d to j.
- In the UV-side of the electrical cabinet, measure the voltage of the UV-lamp on the Terminal Plinth V51X0232, between terminal 1 and 2 for side1 and 11 and 12 for side2. See Chapter 3 Circuit Diagram in the Electrical Manual. Note the voltage.There is a natural variation in voltage between different UV-lamps.
- Attach the clamp around the cable from terminal 1,or 11 depending on which side you are working on, and measure the current to the UV-lamp. Note the current.There is a natural variation in current between different UV-lamps due to voltage variation.

- Terminal Plinth
- Calculate the power (voltage multiplied by current) in VA.Lower power results in lower UV intensity.
| Normal range in 4 kW mode | Normal range in 5 kW mode |
| Voltage | 270 to 300 V | 280 to 310 V |
| Current | 15 to 17 A | 19 to 20 A |
| Power | 4 400 to 4 800 VA | 5 500 to 6 000 VA |
- If the power is too low, reconnect one or more ballasts coils to 380V. See Procedure UV-lamp Ballast Coils - Set Different Voltage.Note: The current to the UV-lamp must not be over 20A at 5kW (the fuse for the UV-lamp is 20A).
UV-lamp - Check Screws for Quartz Glass
| Equipment Status | Power must be turn OFF.
|
- Check the tightness of the six Screw securing the Ring to the UV-lamp house.
- If necessary tighten crosswise the Screw until they have been tightened to the mechanical stop.

- Screw
- Ring
UV-lamp House - Remove Internal Armature
| Equipment Status | Power must be turn OFF.
|
Burn hazard.Allow the UV-lamp and the surrounding parts to cool down before starting any work on them. The UV-lamp and the surrounding parts can be hot.
Hazardous voltage.The circuits of the UV-lamp can contain residual voltage even after the power is turned off. Make sure that the electrical supply disconnecting device is turned off and secured with a lock and that you do the correct short circuit procedure, before starting any work on the UV-lamp.Will shock, burn, or cause death.
- Set the electrical supply disconnecting device in positionO. Wait at least five minutes before you continue to work with the UV-lamp.
- Remove the Hepa box by loosening the Screw.
- Put the Hepa box on a suitable working area.

- Hepa box
- Screw
- UV-lamp housing
- Remove the two pneumatic Hose connected to the UV-lamp housing.
- Move the Cable hose from the machine body over the hygiene chamber, and place them so they easily can be pulled through the cable gland.
- Loosen the counter nuts on the cable gland in the wall.
- Pull the Cable hose through the cable gland in the wall, from the carton section into the hygiene chamber.

- UV-lamp housing
- Hose
- Cable hose
- Loosen the eight end plate Screw and washers that secure the Lamp insert to the UV-lamp housing.
- Pull out the Lamp insert about 50 mm from the UV-lamp housing.
- Disconnect the Earth connection between the End plate and UV-lamp housing.
Risk of damage to the equipment.Handle the internal armature with care.Collisions will cause premature failure of the UV-lamp.
Carefully place the internal armature on a suitable working area.
- UV-lamp housing
- Screw
- Lamp insert
- Earth connection
- End plate
- Set a voltage tester (or multimeter) to AC voltage and a range above 400 V.
- Hold the Test probes against the Phase terminal and the Phase terminal to drain the capacitor.

- Test probes
- Phase terminal
- Phase terminal
UV-lamp House - Check Hose
| Equipment Status | Power must be turn OFF.
|
Burn hazard.Allow the UV-lamp and the surrounding parts to cool down before starting any work on them.The UV-lamp and the surrounding parts can be hot.
Hazardous voltage.The circuits of the UV-lamp can contain residual voltage even after the power is turned off. Make sure that the electrical supply disconnecting device is turned off and secured with a lock and that you do the correct short circuit procedure, before starting any work on the UV-lamp.Will shock, burn, or cause death.
- Check the Hose for wear and damage.
- Follow the pass/fail-table.
| Pass | Fail |
| No cracks | Cracks |
| No wear | Wear |
| No leakage | Leakage |
- If you experience any of the failures, change the hose according to Procedure UV-lamp House - Change Hose.

- Hose
UV-lamp House - Change Hose
| Equipment Status | Power must be turn OFF.
|
| Consumables | Alcoholic Solution (Ethanol 70% or similar) |
Burn hazard.Allow the UV-lamp and the surrounding parts to cool down before starting any work on them.The UV-lamp and the surrounding parts can be hot.
Hazardous voltage.The circuits of the UV-lamp can contain residual voltage even after the power is turned off. Make sure that the electrical supply disconnecting device is turned off and secured with a lock and that you do the correct short circuit procedure, before starting any work on the UV-lamp.Will shock, burn, or cause death.
- Remove the internal armature of the UV-lamp house by following Procedure UV-lamp House - Remove Internal Armature.Note: Remove the markings on the hoses and save them for later.
- Disconnect the Hose, the Electrical cables and the Cable gland from the UV-lamp house.
- Pull out the straight pipe insert from the Hose.

- Hose
- Electrical cables
- Cable gland
- UV-lamp house
- Disconnect the Hose from the Cable gland splice.

- Hose
- Cable gland splice
- Pull off the hose. Make sure that no markings on the Electrical cables fall off.

- Electrical cables
- Cut the new hose to the same length as the old.
- Pull the new Hose on the electrical cables and connect it to the Cable gland splice.Note: If needed, spray alcoholic solution (Ethanol 70% or similar) inside the hose to reduce friction.
- Tighten the Cable gland splice in both ends.
- Repeat items b) to h) for the second hose.

- Hose
- Cable gland splice
- Assemble the straight pipe insert into the end of the hose. Pull the electrical cables through the insert.Note: If needed, spray alcoholic solution (Ethanol 70% or similar) inside the hose to reduce friction.
- Pull the Electrical cables and the Hose through the Cable gland into the UV-lamp house.
- Make sure that the insert is flush with the hose end (see arrow in illustration).
- Connect the Electrical cables.
- Assemble the markings on the Hose.
- Repeat items j) to n) for the second hose.

- Hose
- Electrical cables
- Cable gland
- UV-lamp house
- Assemble the UV-lamp house by following Procedure UV-lamp House - Remove Internal Armature in reverse order.
UV Meter - Basic Setting
| Equipment Status | Power must be turn ON.
|
| Special Equipment | UV-meter TP No. 70000153961 |
Set Autostart- Make sure that the sensor is connected to the instrument.
- Press and hold the Menu button to switch on the UV meter.
- Press the Arrow (down arrow) repeatedly until the settings a menu appears and the arrow points to autostart.
- Press the Left context key (Enter). Then, OFF begins to flash on the display.
- Press the Arrow (down arrow) until on begins to flash on the display. Press the Left context key (Enter).
- Press the Arrow (down arrow) until the arrow points to E(mW/cm2).
- Press the Left context key (Enter). The first digit of five starts flashing.
- Press the Left context key (right arrow) until the fourth digit flashes. Press the Middle context key up arrow until the number 6 flashes.
- Press the Left context key (right arrow) until the sixth digit flashes. Make sure it shows zero.
- Press Left context key (right arrow). The value 60 now appears after E(mW/cm2).
- Make sure that Save mode is deact.
- Press the Middle context key repeatedly until the start menu appears.

- Menu button
- Left context key
- Middle context key
- Arrow
- settings a
- autostart
- deact
Set Auto-off- Press and hold the Menu button to switch on the UV meter.
- Press the Menu button until settings 1 appears on the display.
- Press the Arrow (down arrow) until the arrow points to Auto-off.
- Press the Left context key (Enter). The value then begins to flash.
- Press the Middle context key (up arrow) until 15 min flashes on the display.
- Press the Left context key (Enter).
- Press the Menu button until Input A: appears on the display.

- Menu button
- Left context key
- Middle context key
- Arrow
- settings 1
- Auto-off
UV Meter - Set Offset
To get a correct measurement of the UV-lamp intensity it is important that the offset of the sensor is correctly set. The offset needs to be set when a new sensor is used or if the intensity not is 0.00 mW/cm2. | Equipment Status | Power must be turn ON.
|
| Special Equipment | UV-meter TP No. 70000153961 |
Note: You must perform an offset correction whenever you connect another sensor, or if the device was turned off.- Connect a UV sensor to the Channel A input.
- Press and hold the Menu button to switch on the UV meter.
- Make sure that the display shows Input A: UVC F0.
- If the display does not show,Input A: UVC F0, push the Menu button until Input A: UVC F0 shows.

- Channel A input
- Input A: UVC F0
- Use the flat surface on the top of the Lid to cover the Light inlet aperture of the sensor.
- Press the Left context Key (offset).
- The instrument is ready to use when E shows 0 mW/cm² and Q shows 0 mJ/cm².

- Lid
- Light inlet aperture
- Left context Key
- E
- Q
UV Lamp - Check Intensity
| Special Equipment | UV-meter TP No. 70000153961 UV sensor TP No.70000154043 |
Prepare UV meterThe following equipment is required:UV-meter Sensor Holder Lid.Make sure that the UV-meter is charged. Otherwise, the measurements will be incorrect.The UV-meter must be calibrated once a year by the agency of the manufacturer.- Clean the Sensor using a soft lint-free cloth and alcoholic solution (Isopropanol 70%). See 10.3.2 Chemicals for Cleaning and Disinfection.
- Put the Sensor in the Holder. Make sure that the magnets in the Sensor and the Holder engage, and that the Sensor lies flat in the Holder.
- Put the Lid on the Holder.

- UV-meter
- Sensor
- Holder
- Lid
Activate With XH (only for variant XH)- If you have an XH machine, make sure With XH (only valid for XH machines) is selected. If necessary to select, step up the machine to program step air on.

With (only valid for XH machines)
Prepare MachineBurn hazard.Allow the UV-lamp and the surrounding parts to cool down before starting any work on them.The UV-lamp and the surrounding parts can be hot.
Incorrect valuesMake sure that the quartz glasses are clean and dry. Make sure that the reflector is clean.The quartz glasses must be clean and dry. The reflectors must be clean. Otherwise, the measured values may be incorrect.
- Check the quartz glasses. See Procedure UV Lamp - Check Quartz Glass.
- Check the reflectors. See Procedure UV-Lamp - Check Reflector Sheets.

- Quartz glasses
- Inch the equipment to MSP (Main Shaft Position) 500 - 900.
- Open the doors, and put the Holder-sensor-lid unit in the Cassette, centred under the UV lamp.
Incorrect values.Before using the UV-meter, make sure that the
Cassette is straight by using a
Flathead screwdriver between the plastic links, according to the illustration.If the
Cassette is not straight, the measured values can differ by up to 50% from the correct values.

- Cassette
- Flathead screwdriver
- Holder-sensor-lid unit
Measure UV-intensity- Press and hold the Menu button to switch on the UV meter.
- Make sure that the UV meter offset is correct. See Procedure UV Meter - Set Offset.
- Make sure that the autostart is on. See 5.6.2-23 UV Meter - Basic Setting.
- Press the Right context key (down arrow) two times so that the display looks as shown in the following illustration.

- Right context key
- Place the UV-meter in the UV meter holder and put them in the hygiene chamber.
- Close the door to the hygiene chamber.

- UV-meter
- UV meter holder
- Step up the machine to heating.
- Press Manoeuvre window and Package disinfection.

Manoeuvre windowPackage disinfection
- Press Settings.

Settings
- Select UV-lamp.
- Press Turn on UV-lamp.

NoneTurn on
- Wait two minutes.
- Select Shutter.
- Select Open Shutter.Note: The shutter is open for 20seconds.

Open ShutterShutter
- Read the E value on the UV-meter.

- UV-meter
- E value
- If the E value on the UV-meter reads above A, the UV-intensity is approved. Continue to item Reference. If the E value on the UV-meter reads below A, perform items Reference to Reference.
| A |
| 65 mW/cm2 |
| 70 mW/cm2 (valid for calibration of UV-meter done before October 2020) |
- Change the UV lamp power output to 5kW on the TPOP.
- Perform a new UV intensity check.
- If the intensity is still below A, change the UV lamp. See Procedure UV-lamp - Change.
- After the UV-lamp has been changed, reset the UV lamp power output to 4kW, and perform a new UV intensity check.
- If the intensity of the new UV lamp is below 100 mW/cm2, follow Procedure 5.6.2.2 Troubleshooting.
- Remove all the equipment and move them to the next line on the machine.
- Repeat steps Reference to Reference.

- UV lamp power output
UV-meter - Calibration
| Special Equipment | UV-meter TP No. 70000153961 UV sensor TP No.70000154043 |
The UV-sensor together with the UV-meter are to be calibrated once a year through the agency of the manufacturer.The service technicians or laboratory personnel using the metering device are responsible for the calibration being carried out at the correct intervals.
- UV-meter
- UV-sensor
Troubleshooting - UV-Lamp Intensity
Troubleshooting - Alarms
| Alarm | Probable Cause | Take This Action |
| 110306051/110306052 UV-LAMP, OVERHEATING | Too high temperature in UV lamp housing. | Air filter clogged, replace filter. |
| Sensor V51B1227/ V51B2227 has been disconnected. | Check connection for sensor V51B1227/ V51B2227. |
| Sensor V51B1227/ V51B2227 is broken. | Replace sensor V51B1227/ V51B2227. |
| 110306061/110306062 UV-LAMP, POWER SUPERVISION AT START | UV lamp limiter V51K1004/ V51K2004 incorrectly adjusted | Adjust limiter V51K1004/ V51K2004. See Procedure Control Unit, 3060 - Set UV-lamp Limit. |
| UV lamp limiter V51K1004/ V51K2004 faulty | Replace limiter V51K1004/ V51K2004. |
| 110306071/110306072UV-LAMP, SHUTTER FAULT | UV shutter seized | Make sure that the shutter moves freely. |
| Incorrectly adjusted throttle check valves V51Q3306, V51Q4306/V51Q5306, V51Q6036 | Adjust throttle check valves. See UV-Lamp - Set Shutter. |
| Pneumatic hoses incorrectly connected | Reconnect according to the relevant pneumatic diagram. |
| Pneumatic valve V51K1252/ V51K2252 broken | Replace Pneumatic valve V51K2252/V51K1252. |
| Switch V51B1247/V51B2247 is incorrectly adjusted | Adjust Switch V51B1247/ V51B2247 according to MM. See UV-Lamp - Set Shutter. |
| Switch V51B1247/ V51B2247 is disconnected | Reconnect Switch V51B1247/ V51B2247 according to the EM. |
| Switch V51B1247/ V51B2247 is broken | Replace Switch V51B1247/ V51B2247. |
| 110306081/110306082 UV-LAMP, POWER FAULT | Cables to UV lamp V51E1224/V51E2224 not connected correctly | Connect cables according to the EM. |
| Current relay V51R0002/V51R0003 incorrectly adjusted | Adjust current relay V51R0002/V51R0003. See Procedure Current Control Relay - Set. |
| Current relay V51R0002/V51R0003 malfunctions | Replace relay V51R0002/V51R0003. |
| UV lamp V51E1224/V51E2224 malfunctions | Replace UV lamp V51E1224/V51E2224. |
| 110306121/110306122 UV FAN DRIVE ERROR | UV fan drive V51T1032/V51T2032 malfunctions | Check UV fan drive V51T1032/V51T2032. |
| 110306211/110306212 HIGH TEMP COOLING AIR UV-LAMP | Air filter clogged | Replace air filter. |
| Ambient temperature in filling room is too high. | Adjust ambient temperature. See 1.1.3.1 - Filling Room Temperature, Humidity and Air Quality. in the IM. |
Ejection Chute - Set Proximity Switch
| Equipment Status | Program Step |
- Loosen the Nut.
- Set the distance A between the Proximity switch and the Plate.
Ventilation Hood - Set Proximity Switch
| Equipment Status | Program Step |
- Loosen the Nut.
- Set the distance A between the Proximity switch and the Plate.
Cassette Centring / Opener
Cassette Centring - Set
| Equipment Status | Program Step STEP ZERO |
- Stop the machine with a pair of Sleeve on the pair of mandrels, approaching the Cassette.
- Inch to move the Sleeve forward until they just reach the top edges of the Cassette (to the index position).
- Check that the Forming tubes are correctly set. See Procedure Erector - Basic Set.
- To make sure that the mandrels are in the correct position, remove the Screw and push the Pusher plunger against the inner tools of the mandrels.

- Sleeve
- Cassette
- Forming tubes
- Screw
- Pusher plunger
- Set the Middle support in a position where the gaps between the Sleeve and the Cassette, are the same on both the inner and outer cassettes. See the illustration.
- Lightly push the Fork toward the Holder until the Lug hold the cassette.

A = B
- Sleeve
- Cassette
- Middle support
- Fork
- Holder
- Lug
- Loosen the Screw a ¼ turn.
- Check the gaps C and D, above and below the sleeve. They must be equal.
- If necessary, set the height with the Screw on the LFU side. There is one screw for each cassette centring.
- Tighten the Screw.
- Repeat items Reference to Reference on the second cassette centring.
- Repeat the checks on at least one more pair of cassettes.

C = D
- Sleeve
- Cassette
- Screw
- Screw
Cassette Centring - Set
| Equipment Status | Program Step STEP ZERO |
| Special Equipment | Position template, TP No. 2844893-0200 Position template, TP No. 2984195-0100 Position template TP No. 2844892-0000 (Base) Position template TP No. 2875379-0000 (Midi) Position template TP No. 2931921-0000 (Mini STD) Position template TP No. 3440368-0000 (Mini V) |
- Remove the Position template from the Forming tube template.
- Assemble the Position template to the Forming tube template.

- Position template
- Forming tube template
- Position template
- Step the machine up to tankfilling.
- Inch the machine to sector value 195.
- Open the Forming tube and position the assembled Template according to the illustration.

- Cassette
- Capping station
- Forming tube
- Template
- Slide the Template into the Cassette.

- Cassette
- Template
- Set the Middle support in a position where the gaps, between the Template and the Cassette, are the same on both the inner and outer cassettes. See the illustration.
- Lightly push the Fork toward the Holder until the Lug hold the cassette.

A = B
- Cassette
- Template
- Fork
- Holder
- Middle support
- Lug
- Loosen the Screw a ¼ turn.
- Check gaps C, D, E, and F above and below the Template.Note: All four gaps must be equal.
- If necessary, set the height with the Screw on the CAU side of the hygiene chamber wall. There is one screw for each cassette centring.
- Tighten the Screw.

C = D = E = F
- Template
- Screw
- Screw
- Remove the Volume washer.
- Slide the Template all the way into the bottom of the Cassette.
- If the bottom of the Cassette is not lined up with the Template, continue with item Reference.

- Cassette
- Template
- Volume washer
- Remove the Screw, the Washer, the Washer, and the Cover.
- To make the bottom of the cassette lined up with the template, adjust the drive wheel with the four Screw. If the drive wheel cannot be adjusted, adjust the Clamping element.

- Screw
- Washer
- Washer
- Cover
- Screw
- Clamping element
- Repeat items Reference to Reference on the second cassette centring.
- Repeat the checks on at least one more pair of cassettes.
Cassette Centring - Overhaul
| Equipment Status | Power must be turn OFF. Program Step STEP ZERO |
| Consumables | M5x20, TP No. 312155-0331 Push-in L-Fitting, TP No. 90600-4271 |
Change Lugs
- Push in the Fork.
- Change the four Lug.
- Change the Spacer.

- Fork
- Lug
- Spacer
Overhaul Cylinder
Risk of crushing. Be careful when working near the moving parts.The machine contains moving parts that can crush.
- Disconnect the pneumatic Hose.
- Remove the Screw and Fork screw.
- Remove the Cylinder from the machine and put it on a clean working area.
- Tighten the Fork screw, and push in the fork. Tighten the Screw when the Cylinder is in minus position. Assemble with the new Cylinder, Push-in fitting, and Screw.

- Hose
- Fork screw
- Screw
- Cylinder
- Push-in fitting
- Set the cassette centring. See Procedure Cassette Centring - Set or Cassette Centring - Set.
- Make sure that the cylinder moves smoothly and that no air is leaking from the pneumatic hose connections.Note: If there is a leakage, check if the pneumatic hoses are damaged. If necessary, cut them.
Functional Description
The unit is correctly adjusted when the LEDs on the photocells light upWhen the green lamp lights up there is contact between the transmitter and the receiver.When the red lamp lights up an object is being indicated between the transmitter and the receiver.Photocell Unit - Check
| Equipment Status | Program Step |
- To check the Upper photocell, use tape to fasten a piece of packaging material in front of the upper photocell, and then run the machine.
- This should trigger a stop alarm from the out-feed unit.
- To check the Lower photocell, use tape to fasten a piece of packaging material in front of the lower photocell, run two packages through the machine, and make sure they are thrown out.
- Remove the tape and clean the cover windows with alcoholic liquid.

- Upper photocell
- Lower photocell
Photocell Unit - Set
| Equipment Status | Program Step |
- Remove the Cover.
- Adjust the position of the photocells by using the Screw.
- Put the Cover back.

A = 25±1mm
B = 25±1mm
C = 19±1mm
D = 31±1mm
- Cover
- Screw
Hygiene Cleaning Nozzle Units
Overview

There are 10
Spray nozzle on each side of the non-USA/Canada variant machine.
- Spray nozzle

There are 12
Spray nozzle on each side of the USA/Canada variant machine.
- Spray nozzle

If any of the
Hygiene Cleaning pipe are removed, cover the remaining holes in the hygiene chamber so that no debris enters the cleaning system.
- Hygiene Cleaning pipe
Hygiene Cleaning Nozzle Units - Check
| Equipment Status | Program Step Zero |
Burn hazard.Allow the parts to cool down before starting any work on them.The rotating spray nozzles and pipes are hot during the cleaning and disinfection sequence (program step HCD/HCC).
- Manually rotate all Spray nozzle and check their ability to rotate.
- During a hygiene chamber cleaning (or disinfection) sequence, check if all the Spray nozzle rotate.
- Clean or replace any spray nozzles that does not rotate, according to the procedures Hygiene Cleaning Nozzle Units - Clean Spray Nozzle or Hygiene Cleaning Nozzle Units - Change Spray Nozzle.

The illustration shows the non-USA/Canada machine variant.
- Spray nozzle
Hygiene Cleaning Nozzle Units - Check
| Equipment Status | Program Step Zero |
Burn hazard.Allow the parts to cool down before starting any work on them.The rotating spray nozzles and pipes are hot during the cleaning and disinfection sequence (program step HCD/HCC).
- Manually rotate all Spray nozzle and check their ability to rotate.
- During a hygiene chamber cleaning (or disinfection) sequence, check if all the Spray nozzle rotate.
- Clean or replace any spray nozzles that does not rotate, according to the procedures Hygiene Cleaning Nozzle Units - Clean Spray Nozzle or Hygiene Cleaning Nozzle Units - Change Spray Nozzle.

The illustration shows the non-USA/Canada machine variant.
- Spray nozzle
Hygiene Cleaning Nozzle Units - Clean Spray Nozzle
| Equipment Status | Program Step |
| Special Equipment | Gripping tool |
Burn hazard.Allow the parts to cool down before starting any work on them.The rotating spray nozzles and pipes are hot during the cleaning and disinfection sequence (program step HCD/HCC).
- Hold the Pipe and unscrew the Spray nozzle using a gripping tool at the Key grip.

The illustration shows the non-USA/Canada machine variant.
- Pipe
- Spray nozzle
- Key grip
- Unscrew the Tip and remove the Base from the Spray nozzle body.

- Tip
- Base
- Spray nozzle body
- Remove all debris from the Groove in the Base and the Spray nozzle body.
- Reassemble the Spray nozzle.

- Base
- Spray nozzle body
- Groove
Hygiene Cleaning Nozzle Units - Clean Spray Nozzle
| Equipment Status | Program Step |
| Special Equipment | Gripping tool |
Burn hazard.Allow the parts to cool down before starting any work on them.The rotating spray nozzles and pipes are hot during the cleaning and disinfection sequence (program step HCD/HCC).
- Hold the Pipe and unscrew the Spray nozzle using a gripping tool at the Key grip.

The illustration shows the non-USA/Canada machine variant.
- Pipe
- Spray nozzle
- Key grip
- Remove all dirt from the Inner grooves, the Inner chamber, and the Outer grooves.Note: Never disassemble the cleaning nozzle.
- If the nozzle still does not rotate, either in upright or in horizontal position, flush the nozzle with water and compressed air.
- If the nozzle still does not rotate, either in upright or in horizontal position, prepare a bath with a suitable cleaning solvent. Lower the cleaning nozzle into the bath for 24 hours.
- After 24 hours, flush with water and compressed air to check if the nozzle rotates. If the cleaning head does not rotate easily, either in upright or in horizontal position, it must be replaced. See Procedure Hygiene Cleaning Nozzle Units - Change Spray Nozzle.

- Inner grooves
- Inner chamber
- Outer grooves
Hygiene Cleaning Nozzle Units - Change Spray Nozzle
| Equipment Status | Program Step |
| Special Equipment | Gripping tool |
Burn hazard.Allow the parts to cool down before starting any work on them.The rotating spray nozzles and pipes are hot during the cleaning and disinfection sequence (program step HCD/HCC).
- Hold the Pipe and unscrew the Spray nozzle using a gripping tool at the Key grip.
- Hold the Pipe and fit the new Spray nozzle using a gripping tool at the Key grip.

The illustration shows the non-USA/Canada machine variant.
- Pipe
- Spray nozzle
- Key grip
Hygiene Cleaning Nozzle Units - Change Spray Nozzle
| Equipment Status | Program Step |
| Special Equipment | Gripping tool |
| Consumables | Loctite 2400 TP.No 351532-0050 |
Burn hazard.Allow the parts to cool down before starting any work on them.The rotating spray nozzles and pipes are hot during the cleaning and disinfection sequence (program step HCD/HCC).
- Hold the Pipe and unscrew the Spray nozzle using a gripping tool at the Key grip.
- Hold the Pipe and fit the new Spray nozzle using a gripping tool at the Key grip.Note: Apply one drop of sealant Loctite 2400 directly on the male thread of the pipe.

The illustration shows the non-USA/Canada machine variant.
- Pipe
- Spray nozzle
- Key grip
Diaphragm Valve - Change Diaphragm
| Equipment Status | Program Step |
Remove Actuator
- If the Actuator is in the closed position, move it to the open position.
- Remove the Bolt and the Actuator.
- Move the Actuator to the closed position.
Remove Diaphragm
- Unscrew the old Diaphragm and remove it.
- Clean the parts of the Actuator.
- Make sure that no parts of the Actuator are damaged.
- Replace any damaged parts.

- Actuator
- Bolt
- Diaphragm
Install Diaphragm
- Place the Compressor loosely on the actuator spindle and fit the Groove onto the Guide.
- Make sure that the Compressor fits closely in the Guide.
- Tightly screw the new Diaphragm into the Compressor.
- Make sure that the Diaphragm boss fits closely in the recesses of the Compressor.
- When you feel a clear resistance, turn the Diaphragm counter-clockwise until the bolt holes of the Diaphragm is in alignment with the bolt holes of the Actuator.
Install Actuator
- Move the Actuator to the open position.
- Put the Actuator back on the valve body.
- Install the Bolt and tighten them by hand.
- Move the Actuator to the closed position.
- Fully and evenly tighten the Bolt until the rubber has been compressed by 10-15%.

- Diaphragm
- Compressor
- spindle
- Groove
- Guide
- Diaphragm boss
Diaphragm Valve - Install Position Indicator
| Equipment Status | Power must be turn OFF.
|
- Remove the Nut from the Valve.
- Remove the Rod.
- Install the Mounting kit.
- Install the Position indicator.

- Nut
- Valve
- Rod
- Mounting kit
- Position indicator
Overview

- Valve, S1
- Valve, S2
- Return pump
Pump Unit - Clean the Screen Gasket
| Equipment Status | Power must be turn OFF.
|
| Special Equipment | Tool TP No. 90458-0248 |
| Consumables | Alkali solution (Manual Cleaning) |
Hot parts.Before service, make sure that the pump and pipes are cool before performing this procedure.The pump and the pipelines can cause burn damages.
Remaining hazardous media. Use protective safety equipment: safety glasses, protective gloves and an apron.The pump and the pipes between the pump and the TTCU can contain hazardous media under pressure.
- Carefully open the Clamp and let the media to flow out slowly.
- Remove the Clamp.
- Move the Pipe to the side and remove the Strainer gasket.
- Clean the Strainer gasket carefully with cleaning solution and a brush. A damaged Strainer gasket must be replaced. Rinse the Strainer gasket thoroughly with water.
- Install in the reverse order.

- Clamp
- Pipe
- Strainer gasket
Pump Unit - Dismantle the Return Pump
| Equipment Status | Power must be turn OFF.
|
| Special Equipment | Tool TP No. 90458-0248 |
Remaining hazardous media. Before service, make sure that the pump and the pipes are drained and pressureless. Use protective safety equipment: safety glasses, protective gloves, apron, and respirator with gas vapour filters.The system could contain hazardous media under pressure.
Hot parts.Before service, make sure that the pump and pipes are cool before performing this procedure.The pump and the pipelines can cause burn damages.
- Disconnect the pump from the piping in the connection points.
- Unscrew and remove the Cap nut, the Washer and the Casing Cover.
- Remove the O-ring from the Pump casing.

- Cap nut
- Washer
- Casing Cover
- O-ring
- Pump casing
- Remove the Impeller nut, counter hold the Stub shaft.
- Remove the Impeller from the Stub shaft.
- Remove the Key from the Stub shaft by using a pair of pliers.
- Turn the Stationary seal ring clockwise using the Tool to remove it from the Pump casing.
- Remove the O-ring from the Stationary seal ring.
- Remove the Rotating seal ring, the Spring and the O-ring from Stub shaft.Note: If necessary, place a screwdriver through the hole in the Pump casing and push the seal parts out.

- Pump casing
- Impeller nut
- Stub shaft
- Impeller
- Key
- Stationary seal ring
- O-ring
- Rotating seal ring
- Spring
- O-ring
- Tool
Pump Unit - Overhaul Valve
| Equipment Status | Air must be turn OFF. Program Step STEP ZERO |
| Consumables | Silicone grease: TP No. 344477-0000 |
- Remove the four Bolt and the Cover plate.

- Bolt
- Cover plate
- Disconnect the Proximity switch and the Air connection from the Valve.
- Disconnect the Valve at the Connection.
- Open the Clamp and remove the Valve from the machine.

- Proximity switch
- Air connection
- Valve
- Connection
- Clamp
Risk of crushing.Be careful when working on the valve so that you will not crush your fingers if the air pressure in the valve releases.The
Valve contains a spring that will close the valve if it is not being held open by compressed air.
Remove the lower Clamp and the Lower valve body.- Supply compressed air through the Air connection until the Valve plug releases from the Seat. Do not release the compressed air until told to do so.
- Loosen and remove the Valve plug and the Seat.
- Release the compressed air.

- Air connection
- Clamp
- Lower valve body
- Valve plug
- Seat
- Remove the Upper clamp and the Upper valve body.
Risk of damage to the equipment.Be careful when removing the bushing (14).The bushing (14) will be reused and it can be damaged when it is removed.
Remove the O-ring, the Lip seal, and the Bushing from the Bonnet. Use a bushing tool and a rubber mallet to remove the Bushing.- Install a new O-ring and a new Lip seal.
- Install the Bushing.
- Carefully remove the Plug seal from the Valve plug.
- Carefully install the new Plug seal in the grooves by applying pressure on opposite points on the Plug seal.
- Make sure that any air trapped behind the Plug seal is released.

- Upper clamp
- Upper valve body
- Bushing
- O-ring
- Lip seal
- Bonnet
- Plug seal
Risk of damage to the equipment.Do not overtighten the bushings (19).If you overtighten the bushings (19) you will damage the O-rings.
Loosen and remove the two Bushing.- Replace the O-ring, the O-ring, and the two Bushing. Lubricate the O-rings before replacing them.
- Replace the O-ring on the Seat with new ones.
- Install the Upper valve body with the Upper clamp.
- Supply compressed air through the Air connection until the Valve plug can be fully screwed on and then screw it on.
- Release the compressed air.
- Install the Lower valve body with the lower Clamp.

- Clamp
- Lower valve body
- Valve plug
- Seat
- Upper clamp
- Upper valve body
- Bushing
- O-ring
- O-ring
- O-ring
- Install the Valve with the Clamp.
- Connect the Valve at the Connection.
- Connect the Proximity switch and the Air connection to the Valve.
- Install the Cover plate with the Bolt.

- Bolt
- Cover plate
- Proximity switch
- Air connection
- Valve
- Connection
- Clamp
Hatch - Check Cylinder
| Equipment Status | Program Step |
Risk of crushing.Be careful when working near the moving parts.The machine contains moving parts that can crush.
Use the air service tool to perform the instructions in this procedure. See Section Air Service Tool Description.- Use compressed air (by the arrows) to check the function of the Pneumatic cylinder.
- Make sure that the pneumatic cylinder moves smoothly. If necessary, change the pneumatic cylinder according to Procedure 5.6.8-3 Hatch - Change Cylinder (Valid for the non USA/Canada variants).
- Make sure that the Proximity sensor is activated when the pneumatic cylinder is in the end position. If necessary, change the proximity sensor.
- Check for air leakage at the Pneumatic cylinder by the piston and the pipe couplings. If necessary, change the pneumatic cylinder according to Procedure 5.6.8-3 Hatch - Change Cylinder (Valid for the non USA/Canada variants).

- Pneumatic cylinder
- Proximity sensor
Hatch - Basic Set Cylinder Movement
| Equipment Status | Program Step |
Risk of crushing.Be careful when working near the moving parts.The machine contains moving parts that can crush.
- Close the Throttle check valve.
- Open the Throttle check valve 5 full revolutions.

- Throttle check valve
Hatch - Change Cylinder
| Equipment Status | Program Step |
Risk of crushing.Be careful when working near moving parts.The machine contains moving parts that can crush.
Use the air service tool to perform the instructions in this procedure. See Section Air Service Tool Description.- Disconnect the hoses from the Pneumatic cylinder.
- Remove the Nut.
- Loosen the Nut and the Nut.
- Remove the Pneumatic cylinder from the machine.
- Remove the Rod end.
- Remove the Coupling from the pneumatic cylinder.

- Pneumatic cylinder
- Nut
- Nut
- Nut
- Rod end
- Coupling
- Change the Pneumatic cylinder.
- Assemble the Rod end on the Pneumatic cylinder. Set the distance A according to the illustration.
- Tighten the Nut.
- Assemble the Pneumatic cylinder in the machine, and tighten the Nut.
- Make sure that the Hatch is in the horizontal position, and tighten the Nut.
- Assemble the Pneumatic cylinder in the reverse order.
- Use compressed air to check that the hatch moves from the horizontal position to the vertical position.

A = 10 ±0.5 mm
- Pneumatic cylinder
- Nut
- Nut
- Rod end
- Hatch
HEPA Hatch - Check Cylinder
| Equipment Status | Program Step |
Risk of crushing.Be careful when working near the moving parts.The machine contains moving parts that can crush.
Use the air service tool to perform the instructions in this procedure. See Section Air Service Tool Description.- Check the function of the Pneumatic cylinder.
- Make sure that the pneumatic cylinder moves smoothly. If necessary, change the pneumatic cylinder according to Procedure HEPA Hatch - Change Cylinder.
- Make sure that the Proximity sensor is activated when the pneumatic cylinder is in the end position. If necessary, change the proximity sensor.
- Check for air leakage at the Pneumatic cylinder by the piston and the pipe couplings. If necessary, change the pneumatic cylinder according to Procedure HEPA Hatch - Change Cylinder.

- Pneumatic cylinder
- Proximity sensor
HEPA Hatch - Basic Set Cylinder Movement
| Equipment Status | Program Step |
Risk of crushing.Be careful when working near the moving parts.The machine contains moving parts that can crush.
- Close the Throttle check valve.
- Open the Throttle check valve 2 to 2.5 revolutions.
- Open the Throttle check valve 3 to 3.5 revolutions.

- Throttle check valve
- Throttle check valve
HEPA-channel - Clean
| Equipment Status | Program Step |
- Remove the Internal UV-lamp armature according to UV-lamp House - Remove the Internal Armature.
- Disconnect and remove the Pipes.
- Remove the Bolt that hold the Post and then remove the Post .
- Remove the four Knob and the Perforated HEPA sheet.
- Remove the cleaning nozzle inside the HEPA-channel from the Cleaning nozzle pipe.
- Open and remove the Clamp that holds the cleaning nozzle inside the HEPA-channel and remove the Cleaning nozzle pipe.
- Open and remove the two Clamp and the pipe they hold.
- Remove the Clamp.
- Remove the two Bolt and nut and carefully remove the HEPA-channel from the hygiene chamber and put it on a work table.

- Internal UV-lamp armature
- Pipes
- Bolt
- Post
- Knob
- HEPA sheetPerforated
- Cleaning nozzle pipe
- Clamp
- HEPA-channel
- Clamp
- Clamp
- Bolt and nut
- Mix a detergent solution according to the manufacturers recommendation. See Chemicals for Cleaning and Disinfection in chapter 10 General for recommendations on what chemicals to use.
- Use a brush or sponge to clean the inside of the HEPA-channel. Wipe it dry with a lint free cloth.
Hazardous substances.Always wear personal protective equipment. Read the manufacturer’s instructions and carefully follow the warning texts on the containers. Also see Section Hazardous Substances in the Safety Precautions chapter.Contact with alcoholic solution (Isopropanol 70%) can be hazardous to your health.
Clean the inside of the HEPA-channel with an alcoholic solution (Isopropanol 70%).- Install the HEPA-channel in the reverse order. Install the Internal UV-lamp armature according to UV-lamp House - Fit Internal Armature.
Steering - Set Folder in Pre-folder
| Equipment Status | Program Step |
- Push the Folder to its upper position. Measure the distance A between the Folder and the Inner lid forming tool.
- If the distance A is outside the limits, loosen the Screw and adjust the Folder. Tighten the Screw.

A = 5.0 mm +0.1/-0.0
- Folder
- Inner lid forming tool
- Screw
Doors - Set Fibre Optic Sensor
| Equipment Status | Program Step step zero |
- Set the Bushing, on both sides, according to the table and illustration below.
| A = Base |
| B = Midi |
| C = Mini |
| D = Micro |

- Bushing
The settings above are basic settings. If the alarm package infeed into cassette failed occurs, Do as follows:- check the package is correctly inserted in the cassette.
- fine adjust the settings so that the alarm does not occur.
Functional Description
The Cassette Conveyor is driven by a Servomotor, through a Planetary gear (gear ratio 80:1) and two bevel gear boxes (Bevel gearbox VV1 and Bevel gearbox VV2 (gear ratio 2:1)). It is synchronised with the other movements in the machine through the PLC system.The system cannot be cranked by hand. It must be driven using the inch button on the panel.Oil level sensors are built in to the bevel gearboxes VV1 and VV2. If an oil level is low, an alarm on the panel signals. The alarm only signals if the machine has been out of operation for more than one hour. During operation, the oil is tossed around in the gears, which could result in false alarms. The planetary gear (2) is filled with grease.All four drive shafts are equipped with a Safety clutch that releases at 250Nm. A Proximity switch senses when the clutch releases and stops the machine.
- Servomotor
- Planetary gear
- Proximity switch
- Safety clutch
- Bevel gearbox VV1
- Bevel gearbox VV2
Drive Unit - Check Oil Levels
| Equipment Status | Program Step STEP ZERO |
| Consumables | Oil |
Check oil level in the gears. (for specifications, see Chapter General)| Gear | Oil type | Volume litre | |
| VV1 | 344410-0000*90458-2734** | 1.5 | |
| VV2 | 344410-0000*90458-2734** | 2.75 | |
| PV1 | 90459-3752 | 0.1 | |
| PV2 | 90459-3752 | 0.3 | |
| *Valid from machine 63202/20067 or for machines with UK-3355833-0100.**Valid for machines up to 63202/20066, without UK-3355833-0100. |

- Level guard
- Level guard
Bevel Gears VV1 and VV2 - Fit
| Equipment Status | Program Step |
- Mount the bevel gears VV1 and VV2, and align them by the guide pins.
- Tighten the mounting screw to 76 Nm and 187 Nm, according to the illustration below. Check by the aid of a 0.05 mm feeler gauge, that the gears bear against the guide pins.
Intermediary Shaft - Fit
| Equipment Status | Program Step |
Mount the intermediary shaft between VV2 and VV1.- Apply thin oil to the Screw of the clamp elements.
- Centre the couplings and tighten the Screw to 130 Nm. At tightening, check that the gaps A and B are equal.

- Screw
Safety Clutch, Proximity Switch - Set
| Equipment Status | Program Step STEP ZERO |
Set the proximity switch sideways and adjust the gap, according to illustration.Shafts and Couplings - Fit
| Equipment Status | Program Step STEP ZERO |
- The shafts/couplings must not be lubricated before assembling.
- The outer parts of the shafts/couplings are to be cleaned by degreasing compound (for transmitting correct turning moment).
- The Coupling and Coupling are mounted with the deepest shaft hole facing the gear box.
- At mounting, push the Coupling against the shaft collar. For Coupling, see illustration.
- Apply oil or grease to the screws of the Coupling and Coupling. Tighten the coupling screws to 130 Nm. At tightening, check that the distance A and B are equal.

- Coupling
- Coupling
- Tighten the Screw to 35 Nm.
- Protect the Shaft, and the gear box shaft bars, against corrosion by for example Dinitrol Car.Note: The Coupling should already be tightened. The Coupling are to be tightened later, in connection with setting of conveyor.
See illlustration:*Measurement from tightening cover to shaft end.**Measurement to facilitate mounting.
- Screw
- Shaft
- Coupling
- Coupling
Homing (Set the Index Position)
Drive Unit - Homing
| Equipment Status | Program Step |
| Special Equipment | Keyboard |
Note: This homing is only to be done after the servomotor has been changed.- Connect a keyboard to the TPOP.
- Press the F4 button on the keyboard to open the Technical Menu.
- Press the Servo button to open the Servo Technical window.

- Servo button
- Press the Reset button to reset the home position.
- Exit the Servo Technical window and the Technical Menu.
- Step the machine up to air on.Note: This will cause an alarm about the servomotor position.
- Reset the alarms to make it possible to do the following items.
- Inch the conveyor so that one of the Cassette is in the right-angle position that is shown in the illustration. Note: This is called the “index position”.
- Press the F4 button on the keyboard to open the Technical Menu.
- Press the Servo button to open the Servo Technical window.
- Press the Calibrate button to do the calibration.
- Exit the Servo Technical window and the Technical Menu. Press
Save before you exit.Note: The alarm regarding the servomotor position will now disappear. - Do the setting procedure according to Cassette Assemble - Set.
- Reset button
- Cassette
- Calibrate button
Cassette Lift, Filling - Overhaul
| Equipment Status | Program Step |
Risk of damage to the equipment.Be careful when you remove the
Ball bushing.The cylinder housing can be damaged when you remove the
Ball bushing.
Change the Fork, O-ring, Seal, Ball bushing, Rubber ring and the O-ring. Discard the removed parts. See below for more information. See the illustration on the next page.- Make sure that there is no blockage in the Oil channel. Use an airgun to do this.
- Install the new Ball bushing with the upper seal ring of the bushing turned outwards from the column and the seal ring of the lower bushing turned downward. They must also be turned outwards from the column.
Risk of damage to the seals.Use blunt tools and be careful when installing the
Seal.Sharp tools can damaged the
Seal and cause leaks.
Install the Seal in the Ring. Squeeze the Seal by hand to make them fit in the Ring. Use a suitable blunt tool to push the Seal into position according to the illustration on the next page.- Make sure that the Oil channel in the column lines up with the Oil channel in the flange.
- Set the cassette lift according to Cassette Lift, Filling - Set.
- Check the cassette lift according to Cassette Lift, Filling - Check.

- Fork
- Ball bushing
- O-ring
- Seal
- Rubber ring
- O-ring
- Oil channel
- Ring
- Oil channel
Servo Lift Sealing - Check Belt and Bearings
| Equipment Status | Program Step |
- Check the Belt for any visible damage:
- broken teeth
- uneven surface
- the edge of the belt is broken
- corrosion of the cord
- If the Belt has any visible damage, change belt and bearing according to Servo Lift Sealing - Change Belt and Bearings.

- Belt
Servo Lift Sealing - Change Belt and Bearings
- Release the Belt tension screw.
- Remove the Screw and pull out the servomotor, gearbox, and Flange, as a unit.
- Disconnect the Clamp bracket and take out the Tension unit and belt.
- Change Belt and Bearing.
- Check the Coupling for play and, if necessary, change it.
- If the coupling has to be changed, note its position (distance from shaft end); fit back at the same position. Assemble and set according to Servo Lift Sealing - Assemble.

- Belt tension screw
- Screw
- Flange
- Clamp bracket
- Tension unit
- Belt
- Bearing
- Coupling
Servo Lift Sealing - Assemble
| Equipment Status | Program Step |
- Fit the Shaft and the Shaft; make sure that the shaft ends reach the bottom of the Coupling contact surfaces. Use white spirit and wipe off shafts and coupling before fitting. Also lightly apply oil to the screws of the coupling, and tighten to 8Nm.
- Fit the Servomotor. Tighten the Socket screw, securing the motor shaft to the gear box, to 14Nm.Note: Plug the Hole.
- To achieve the correct belt tension, set the distance A with the Screw.

A = 103.4 mm
- Shaft
- Shaft
- Coupling
- Servomotor
- Socket screw
- Hole
- Screw
Servo Lift Discharger - Check Belt
| Equipment Status | Program Step |
- Check the Belt for any visible damage:
- broken teeth
- uneven surface
- the edge of the belt is broken
- corrosion of the cord
- If there is any visible damage, change the Belt according to Servo Lift Discharger - Change Belt and Bearings.

- Belt
Servo Lift Discharger - Change Belt and Bearings
| Equipment Status | Program Step STEP ZERO |
Risk of crushing.Be careful when working near the moving parts.There are moving parts in the machine.
- Release the pneumatic brake (side 2) by pressurizing it slowly. The discharger units will fall down to their lowest position.
- Release the belt tension Belt tension screw.
- Disconnect the Clamp bracket.
- Unscrew the Screw.
- Disconnect the Coupling on the transfer shaft.

- Belt tension screw
- Clamp bracket
- Coupling
- Screw
- Coupling
- 10Belt
- Pull out the servomotor, gearbox, flange, and sprocket as a unit.
- Change belt and bearings.
- Check the Coupling for play and, if necessary, change it.
- If the coupling has to be changed, note its position (distance from shaft end); refit at same position. Assemble and set according to Procedure Servo Lift Discharger - Assemble.
Servo Lift Discharger - Assemble
| Equipment Status | Program Step PROGRAM STEP ZERO |
- Assemble group A (S1) (see illustration) by following Procedure Servo Lift Discharger - Change Belt and Bearings.Note: When mounting the Coupling, use alcohol and wipe of shafts and coupling before fitting. Also lightly apply grease to the screws of the Coupling, and tighten to 8 Nm.
- Assemble group B (S2) (without servomotor and gear box).
- Set the distance C, to achieve the correct belt tension, by the Belt tension screw.

C (mm)= 103.4
- Belt tension screw
- Coupling
- Move the Discharger to the correct position in accordance with the belt.
- Loosen the Screw to adjust. Make sure that the Column is in close contact with the Guide pin.

- Discharger
- Screw
- Column
- Guide pin
- Fit the Intermediary shaft by tightening the Clamping screw on both sides.
- The dischargers are to be in their lowest position, and at same level (check by measuring their height). Tighten the Clamping screw to 15 Nm.

- Intermediary shaft
- Clamping screw
- Coupling
- Make sure that the measure A is the same as measure B.
- Assemble the servo motor and gear box.

A=B
- Intermediary shaft
Servo Lift Discharger - Prepare for Maintenance
| Equipment Status | Program Step STEP ZERO |
Risk of crushing.Follow this instruction to perform safe work.If this instruction is not followed, there is a risk of crushing fingers.
Note: Only one side of the machine must be stepped up. This instruction handles side 1.- Step up side 1 of the machine to AIR ON.
- Step up side 1 of the machine to PREHEATING.
- Press Manoeuvre window.
- Press Carton section.

Manoeuvre windowCarton section
- Press Web-preparation.
- Press the 1 button. The Web-preparation button turns green.
- The symbol for production changes from a package symbol to a Mailbox symbol.
Web-preparation1 button- Mailbox symbol
- Step up side 1 of the machine to Tank filling.

- Tank filling
- Use the INCH button to inch the machine until the discharger reaches its lowest position. For information regarding lowest position, see section Additional Check in Procedure Gripper Fingers, Height - Check.
- Step down side 1 of the machine to step zero.Note: The Web-preparation function is automatically deactivated.

- INCH button
Servo Lift Discharger - Change Belt and Bearings
| Equipment Status | Program Step STEP ZERO |
Risk of crushing.Follow this instruction to perform safe work.If this instruction is not followed, there is a risk of crushing fingers.
- Follow Procedure Servo Lift Discharger - Prepare for Maintenance to lower the discharger to its lowest position.
- Release the belt tension Belt tension screw.
- Disconnect the Clamp bracket.
- Unscrew the Screw.
- Disconnect the Coupling on the transfer shaft.

- Belt tension screw
- Clamp bracket
- Coupling
- Screw
- Coupling
- Pull out the servo motor, gearbox, flange, and sprocket as a unit.
- Change belt and bearings.
- Check the Coupling for play and, if necessary, change it.
- If the coupling has to be changed, note its position (distance from shaft end); refit at same position. Assemble and set according to Procedure Servo Lift Discharger - Assemble.
Servo Lift Filling - Change Timing Belt and Ball Bearings
| Equipment Status | Program Step |
- Release the Belt tension screw.
- Disconnect the Clamp bracket.
- Unscrew the Screw and take away the servomotor.
- Remove the Flange and pull out the Sprocket.
- Change timing belt and ball bearings. Apply locktite to lock the Ball bearing to the shaft.
- Check the Coupling for play and, if necessary, change it.
- If the coupling has to be changed, note its position (distance from shaft end); refit at same position. Assemble and set according to Servo Lift Filling - Assemble.

- Belt tension screw
- Screw
- Coupling
- Flange
- Clamp bracket
- Sprocket
- Ball bearing
Servo Lift Filling - Assemble
| Equipment Status | Program Step |
- Assemble group A (see illustration).
- Fit the coupling halves level to the shafts. Use white spirit and wipe of shafts and coupling before fitting. Also lightly apply oil to the screws of the coupling, and tighten to 8 Nm.
- Fit the servomotor (B).
- Set the distance 103.4 mm, to achieve the correct belt tension, by the Belt tension screw.

- Belt tension screw
Servo Sidefeeder - Set Pusher Spade
| Equipment Status | Program Step STEP ZERO |
| Consumables | Thread locker: TP. No. 351532-0000 |
- Remove the Bolt and washer on side 1.
- Move the A-spacer, the B-spacer and the Pusher spade on side 1 to the correct configuration for the bottom size on side 1, according to the illustration.
- Install and tighten the Bolt and washer. Use thread locker on the bolt.
- Make sure that both sides are set to the correct configuration.

- Bolt and washer
- A-spacer
- B-spacer
- Pusher spade
Servo Sidefeeder - Set Belt Tension
| Equipment Status | Program Step |
| Special Equipment | Belt tension meter, TP No. 90609-7425 |
| Consumables | Protection plug, TP No. 90459-3200 |
- Remove the protection plug under the Axle on the side 1 hygiene chamber wall.Note: It might be necessary to break the protection plug to remove it.
- Tighten or loosen the Bolt to set the measurements A and B. Measure through the two Hole.
- Check the Timing Belt tension with a Belt tension meter. Belt tension should be 104 Hz.
- Install a new protection plug.

A (mm) = 15 ± 0.2
B (mm) = 15 ± 0.2
- Axle
- Bolt
- Hole
- Timing Belt
Servo Sidefeeder - Prepare for Maintenance
| Equipment Status | Program Step |
Remaining media.Before service, make sure that the valves and the pipes are drained and pressurelessThe cleaning system could contain media under pressure.
- Open the Door.
- Remove the Front plate.
- Disconnect and remove the Pressure gauges.
- Disconnect the Flow meter at the Connection.
- Remove the two Pipe, with the Flow meter and the non-return valves still attached.

- Door
- Front plate
- Pressure gauges
- Flow meter
- Connection
- Pipe
- Remove the Plate.
- Remove the Pipe.
- Remove the Valve group.
- Remove the Pipe.

- Plate
- Pipe
- Valve group
- Pipe
Volume Change Mechanism - Check
| Equipment Status | Program Step |
Note: If the check function is aborted, the volume change mechanism will be reset to the zero position.- Insert and activate the service key. The Service window appears.
- Open the volume change window by pressing the PS Service for the correct side of the machine.
- Deactivate the service key.
- The Inch button on the package section lights up and becomes active.
- Service window
- PS Service
- Inch button
- Press and hold the Inch button . The machine will stop with the Shifting between two Cassette.
- Press Forward on the remote control so that the actuator goes to the volume position.
- Inch the machine forward so that a Volume washer is gripped by the Shifting.
- Inch button
- Shifting
- Cassette
- Forward
- Volume washer
- Set a test volume in the Test volume menu.Note: If you want to test the current volume only, use the same volume in both menus. The current menu will be preset.
- Press the Forward button once.
- Retract and insert the Volume washer by pressing the Toggle button repeatedly to check the setting of the volume change mechanism for the current volume. If the setting is incorrect, set the volume change mechanism again.
- If necessary, check a second volume:
- Reset the volume change mechanism by pressing Back until the volume washer is in the current volume position.
- Inch the machine until the Shifting is between 2 Cassette. When the volume change mechanism is shut off, it will reset to the zero position.

- Forward
- Test volume
- Toggle
- Back
Volume Change Mechanism - Check Cylinder
| Equipment Status | Program Step |
Risk of crushing. Be careful when working near moving parts.The machine contains moving parts that can crush.
- Check for air leakage at the Cylinder by the pistons and the pipe couplings. On Festo machines, use the air service tool. See Air Service Tool Description.
- If necessary, overhaul the cylinder according to Procedure Volume Change Mechanism - Overhaul Cylinder.

- Cylinder
Volume Change Mechanism - Set
| Equipment Status | Program Step |
Risk of damage to the equipment.Do not inch or run the machine with the volume plates in the cassettes before the volume adjuster has been set.
- Mark the position of the rear cassette wheel.
- Loosen the clamp on the drive shaft.
- Remove eight cassettes to make it possible to set the inner volume shifting head.
- Disconnect the Ball link.
- Loosen the Bolt and adjust the clear length of the Rod end to the distance A. (Do not tighten the screws yet).

A (mm) = 16 to 18
- Ball link
- Bolt
- Rod end
- Put 2 mm Distance piece under each Shifting head to get an equal height for both. Check that the shifting heads are parallel with a Ruler.
Risk of damage to the bolts.Do not tighten the
Bolt unevenly or too much. Both uneven tightening and to much torque can damage the bolts.
Tighten the Bolt, equally and in steps, to 22Nm. - Remove the Distance piece.
- Turn the Rod 360° clockwise to be sure that it is in its lowest position.

- Distance piece
- Shifting head
- Ruler
- Rod
- Put the shifting cylinders to their outer position (by hand), and set the horizontal distance B between the Shifting and Cassette guide. Do this by loosening the Bolt, and sliding the cylinder to the correct position. Then tighten the screws.
- Set the height of the shifting heads to the distance C by adjusting the Ball link. Connect the ball link and tighten the Counter nut.Note: When measuring, make sure the Cassette is resting on both of the lower guides.
| B (mm) | C (mm) |
| 117.0 ±0.5 | 165.0 -0.5 (Base)163.0 -0.5 (Midi/Mini) |

- Shifting
- Cassette guide
- Bolt
- Counter nut
- Cassette
- If the Mecman sensor is used, make sure that the End limit sensor is positioned as far down as possible. This is so that the End limit sensor can be used in homing the actuator.If the Sick sensor is used, make sure that the tip of the End limit sensor is positioned 4.6 mm above the bottom surface on the linear actuator. This is so that the End limit sensor can be used in homing the actuator.
Risk of damage to the volume plate.The guide studs have to be turned outwards, otherwise they would crash against the volume plate.
Set the distance between the Upper guide stud and Lower guide stud, by inserting a volume plate between them, and turning the Lower guide stud. The volume plate has to move stiffly between the studs, which means that the distance between the studs must be 0.1 - 0.2mm smaller than the volume plate.- Put the eight cassettes back.
- Reset the cassette wheel.
- Tighten the clamp screws to 130Nm.
- To define zero-position for the device, move it up a bit, step the machine to program step Air On and then flip the service key to on and off again.
- Check the setting of the volume change mechanism according to Volume Change Mechanism - Check.

- End limit sensor
- Upper guide stud
- Lower guide stud
Volume Change Mechanism - Overhaul Cylinder
| Equipment Status | Power must be turn OFF. Program Step STEP ZERO |
| Consumables | M6x25, TP No. 312155-0372 M8x25, TP No. 312155-0453 Thread locker, TP No. 351532-0000 |
Risk of crushing. Be careful when working near the moving parts.The machine contains moving parts that can crush.
- Disconnect the Pneumatic hose and remove the Push-in fitting.
- Remove the Screw, the Fork, and the four Screw.
- Slide out the Cylinder. If necessary, loosen the two Screw.

- Pneumatic hose
- Push-in fitting
- Screw
- Fork
- Screw
- Screw
- Cylinder
- Assemble in the reverse order with a new cylinder, a new Screw, and new Screw.If necessary, change the push-in fittings.
- Make sure that the cylinder moves smoothly and that no air is leaking from the pneumatic hose connections.Note: If there is a leakage, check if the pneumatic hoses are damaged. If necessary, cut them.
Volume Change DC-Motors - Set Current Limit
| Equipment Status | Program Step HEATING |
| Special Equipment | Template TP. no. 2734157-0101 |
Risk of damage to the equipment.Always check that the shifters are in their lowest position before running the machine.If the shifters are not in their lowest position, they can collide with other parts when the machine is running.
Note: During this setting, several alarms appear that must be reset. - Set the ramp time control on the current limit-circuit to 80ms (centre position). See Procedure Motor Drive Control - Set on page Motor Drive Control - Set.
- Turn the Limit value/Amp control to about 5 amps. See Procedure Motor Drive Control - Set.
- Fit the Template according to the illustration.
- Close the doors and reset the door alarm on the TPOP.

- Limit value/Amp control
- Template
- Insert and activate the service key. The Service window displays.
- Open the volume change window by pressing the PS Service for the correct side of the machine. The Inch button on the package section lights and becomes active.
- Press and hold the Inch button . The machine stops with the Shifting between two Cassettes.
- Service window
- PS Service
- Inch button
- Shifting
- Cassettes
- Run the volume change unit upwards by pressing the Up button. The unit stops automatically.
- Measure the length of the Template spring. With the correct setting, the length is between 60 and 70mm.
- Lower the unit again by pressing the Down button.
- If the distance is wrong, adjust the potentiometer slightly with the amp control. Repeat items Reference to Reference until the correct spring length is reached.
- When the current limit is correct, lower the unit by pressing the Down button.
- Remove the Template.
- Run the device up about 50-100mm.
- Reset any alarms on the TPOP.

- Template
- Up button
- Template spring
- Down button
Motor Drive Control - Set
Risk of damage to the drive.Make sure that the power supply has the correct polarity and that an external fuse is used.An incorrect polarity can damage the drive.
- Set the ramp time with the Ramp time control.
- Set the current limit value/Amps with the Limit value/Amp control.Note: The current limit values can be affected by the used motor. During the first 0.3 s of the start-up the current limit value is doubled.Note: If the motor drive control is to be replaced, check the position of the two bridges. The Control mode must be in the left hand position and the TRIP in the right hand position).

A (mm) = 39
B (mm) = 43
C (mm) = 68
D (mm) = 73
E (mm) = 23
F (mm) = 5 (free space required at the bottom side)
- Ramp time control
- Limit value/Amp control
- Control mode
- TRIP
Overview
| Pos | Description | Function no. Side 1 | Function no. Side 2 |
| 1 | Drain cleaning box valve | V61M1256 | V61M2256 |
| 2 | Steam trap valve | V61M1257 | V61M2257 |
| 3 | Non return valve | | |
| 4 | Main return valve | V61M1255 | V61M2255 |
| 5 | Steam trap | V61V2258 | V61V1258 |
| 6 | Pressure gauge | A66B1215 | A66B2215 |
| 7 | Flow meter | A66Q1235 | A66Q2235 |
Non Return Valve - Check Seals and Spring
| Equipment Status | Program Step |
Remaining media.Before service, make sure that the valves and the pipes are drained and pressurelessThe cleaning system could contain media under pressure.
Note: The Non return valve contains a spring. The parts inside the valve can pop out unexpectedly, resulting in loss of the spring or other parts.- Disassemble the Clamp ring and pull apart Valve body and Valve body to expose the Valve cone and Guide plate.
- Visually inspect the condition of the Seat seal, the Spring, and Seal ring.
- If required, change according to the procedure Non Return Valve - Change Seals and Spring.
- If required, clean the valve according to the procedure Non Return Valve - Clean.
- When assembling, ensure that the Valve cone is lined up with the Valve body.

- Valve body
- Valve body
- Valve cone
- Guide plate
- Clamp ring
- Seal ring
- Seat seal
- Spring
CIP Flow Meter - Set
| Equipment Status | Program Step |
Hot parts.Let the flow meter cool down before you do any work on it.The flow meter is hot when it has been in use.
- After a successful function check, switch on the measuring device.Note: After a successful startup, the local display automatically switches from the startup display to the operational display.
- Navigate to the
Setup menu.Note: The Setup menu contains all the parameters needed for standard operation. - To enter the
Setup menu, press E. - To go back to the previous menu options, press Esc.
- To jump to the language settings, press E.Press E to change the language.Note: The default language is English.
- To exit the language settings, press Esc (the - and the + buttons at the same time).
- Press E to enter the
Main menu. - Go down to the
Setup menu and press Enter. - Go down to the
System units menu and press Enter. - Go to the
Volume flow unit menu and press Enter.
- Select m3/h and press Enter to confirm.
- To go back to the previous menu options, press Esc.
- Go down to the
Curr.output 1 menu and press Enter. - Select the
Assign curr. 1 menu option and press Enter.
- Go down to the
20 mA menu option and press Enter. - Select
5 and press Enter. - Select
0 and press Enter. - Select the check symbol
and press Enter.Note: The 20 mA value must correspond to 50 m - Finish the setup by pressing Esc three times.
Disable Totalizer (Optional)
- Press E, then go to the
Setup menu by pressing E again. - Go to the
Advanced setup menu and press E.
- Go to the
Totalizer 1 menu and press E. - Press E again and set the value to
Off. - Finish the setup by pressing Esc four times.
- To set Totalizer 2, repeat items Reference to Reference.
Setting the CIP Flow Meter (Older Variant)
Risk of burns.Let the flow meter cool down before starting any work on it.The flow meter is hot when it has been in use.
Note: Press the Minus button and the Plus button simultaneously to abort the current selection without saving. Press and hold the same buttons for three seconds to abort the setting procedure.- Loosen the four Screw fully and remove the Cover. The Screw cannot be removed from the Cover.
- Press the E button to enter the
Group select Mode.Note: When you press a button, you need to hold it for about one second. - Press the Plus button one time to step to
System Units. 
- Minus button
- Plus button
- Screw
- Cover
- E button
- Press the E button to enter the
System Units menu. - Press the Plus button one time to enter the
Unit volume flow menu. The flow meter will ask you to enter an access code. - Enter the access code 0050 using the following method:
- Use the Plus button and the Minus button to step up or down the digits.
- Press the E button to confirm a digit and to step to the next one.
- Press the E button to unlock the programming menu when all the four digits are entered. The display will show: PROGRAMMING ENABLED.
- Use the Plus button and the Minus button to step the blinking volume unit to m.
- Press the E button to confirm the volume unit and to step to the time unit.
- Use the Plus button and the Minus button to step the blinking time unit to h.
- Press the E button to confirm the time unit.
- Press the E button three times to step back to the group select mode.
- Press the Plus button three times to step to the USer interface menu.
- Press the E button to enter the USer interface menu.
- Press the E button one time to step to the Assign Line 2 menu.
- Press the Plus button four times to step to the operating/system condition option.
- Press the E button to confirm that you want to change the setting.
- Press the E button six times to step back to the group select mode.
- Press the Plus button one time to step to the Totalizer 1 menu.
- Press the E button to enter the Totalizer 1 menu.
- Press the Plus button one time to enter the Assign totalizer menu. The display shows: “
Volume flow”. - Press the Plus button one time to change
Volume flow to OFF. - Press the E button. The flow meter will ask if you are sure that you want to change the setting.
- Press the Plus button one time to change the No to Yes.
- Press the E button to confirm that you want to change the setting.
- Press the E button one time to step back to the
Group select mode. - Press the Plus button one time to step to the Totalizer 2 menu.
- Press the E button to enter the Totalizer 2 menu.
- Repeat items Reference to Reference.
- Press the Plus button one time to step to the Current output menu.
- Press the E button to enter the Current output menu.
- Press the E button one time to step to the current span menu.
- Press the Plus button two times to step to the
4-20 mA HART option. - Press the E button to confirm that you want to change the setting.
- Press the E button one time to step to the
VALUE 20 mA menu. - Press the Plus button one time and enter the value +50.000 using the following method:
- Use the Plus button and the Minus button to step up or down the digits.
- Press the E button to confirm a digit and to step to the next one.
- Press the E button enter the value when all the digits are entered.
- Press the E button five times to step back to the
Group select mode. - Press and hold the Minus button and the Plus button simultaneously for 3 seconds to exit the
Group select mode. - Install the Cover with the Screw.
Non Return Valve - Clean
| Equipment Status | Program Step |
| Special Equipment | Cloth |
Remaining media.Before service, make sure that the valves and the pipes are drained and pressurelessThe cleaning system could contain media under pressure.
Note: The Non return valve contains a spring. The parts inside the valve can pop out unexpectedly, resulting in loss of the spring or other parts.- Disassemble the Clamp ring and pull apart the Valve body and Valve body to expose the Valve cone and Guide plate.
- Use cloth to clean the Valve body, Valve body, Valve cone and Guide plate.
- When assembling, ensure that the Valve cone is lined up with the Valve body.

- Valve body
- Valve body
- Valve cone
- Guide plate
- Clamp ring
Steam Trap - Remove
| Equipment Status | Program Step |
Remaining media.Before service, make sure that the valves and the pipes are drained and pressureless.The cleaning system could contain media under pressure.
Hot parts in the cleaning system.Use caution when working inside the cleaning system.Pipes and components in the cleaning system can cause burn damages.
- Disconnect the Pipe.
- Remove the Screw and lift out the Steam trap together with the Bracket.

- Pipe
- Screw
- Steam trap
- Bracket
CIP Flow Meter - Remove the Wiring
| Equipment Status | Power must be turn OFF.
|
Hazardous voltage.The main power supply disconnector must be switched off and secured with a lock before starting any work on the wiring.Will shock, burn or cause death.
Risk of burns.Let the flow meter cool down before starting any work on it.The flow meter is hot when it has been in use.
- Disconnect the power supply circuits.
- Remove the Screw and the Cover.
- Disconnect the Wire from the Terminal.
- Loosen the Cable gland.
- Pull the Cable out of the Cable gland.

- Screw
- Cover
- Wire
- Terminal
- Cable gland
- Cable
Non Return Valve - Change Seals and Spring
| Equipment Status | Program Step |
Remaining media.Before service, make sure that the valves and the pipes are drained and pressurelessThe cleaning system could contain media under pressure.
Note: The non return valve contains a spring. The parts inside the valve can pop out unexpectedly, resulting in loss of the spring or other parts.- Disassemble the Clamp ring and pull apart the Valve body and Valve body to expose the Valve cone and Guide plate.
- Change the Seat seal, the Spring, and the Seal ring.
- When assembling, ensure that the Valve cone is lined up with the Valve body.

- Valve body
- Valve body
- Valve cone
- Guide plate
- Clamp ring
- Seal ring
- Seat seal
- Spring
CIP Flow Meter - Change the Transmitter (Old Version)
| Equipment Status | Power must be turn OFF.
|
Hazardous substances.Make sure that the pipeline is drained before starting any work on the flow meter.The pipeline that the flow meter is connected to may be full of hazardous substances.
Risk of burns.Let the flow meter cool down before starting any work on it.The flow meter is hot when it has been in use.
Remove
- Remove the wiring according to CIP Flow Meter - Remove the Wiring. (Do not do this if you only need to turn the transmitter.)
- Loosen the two Bolt.
- Carefully lift the Flow meter from the flow meter.

- Bolt
- Transmitter
Install
- Lower the Flow meter onto the flow meter.
- Fasten the Flow meter to the flow meter with the two Bolt.
- Install the wiring according to CIP Flow Meter - Install the Wiring.
CIP Flow Meter - Change the Transmitter (New Version)
| Equipment Status | Power must be turn OFF.
|
Hazardous substances.Make sure that the pipeline is drained before starting any work on the flow meter.The pipeline that the flow meter is connected to may be full of hazardous substances.
Risk of burns.Let the flow meter cool down before starting any work on it.The flow meter is hot when it has been in use.
Remove
- Remove the wiring according to CIP Flow Meter - Remove the Wiring. (Do not do this if you only need to turn the transmitter.)
- Loosen the eight Bolt.
- Carefully lift the Flow meter from the Pipe connection.

- Bolt
- Flow meter
- Pipe connection
- Transmitter housing
Install
- Before installing the new flow meter, the Seal need to be changed. There is one seal on each side of the flow meter.
- Lower the Flow meter so that it is placed between the Pipe connection.
- Tighten the Bolt until the Pipe connection touch the flow meter.Note: The metal against metal connections between the pipes and the flow meter ensures a defined compression of the Seal.
- Install the wiring according to CIP Flow Meter - Install the Wiring.
- Set the new flow meter according to CIP Flow Meter - Set.

- Seal
Rotate Transmitter Housing
Valid for: S2

- Securing clamp
- Connection compartment cover
- Fixing screw
Rotate the transmitter housing according to how the replaced transmitter housing was rotated.- Depending on the device version, loosen the Securing clamp of the Connection compartment cover.
- Unscrew the Connection compartment cover .
- Release the Fixing screw.
- Turn the housing to the desired position.
- Firmly tighten the Fixing screw.
- Screw on the Connection compartment cover.
- Depending on the device version, attach the Securing clamp of the Connection compartment cover.
CIP Flow Meter - Change the Seals
| Equipment Status | Power must be turn OFF.
|
Hazardous substances.Make sure that the pipeline is drained before you starting work on the flow meter.The pipeline that the flow meter is connected to may be full of hazardous substances.
Risk of burns.Let the flow meter cool down before starting any work on it.The flow meter is hot when it has been in use.
- Remove the Bolt.
- Change the Seal. There is one seal on each side of the flow meter.
- Tighten the Bolt until the Pipe connection touches the flow meter.Note: The metal against metal connections between the pipes and the flow meter ensures a defined compression of the Seal.

- Bolt
- Seal
- Pipe connection
CIP Pressure Gauge - Change the Transmitter
| Equipment Status | Power must be turn OFF.
|
Hazardous substances.Make sure that the pipeline is drained before starting any work on the pressure gauge.The pipeline that the pressure gauge is connected to may be full of hazardous substances.
Risk of burns.Let the pressure gauge cool down before starting any work on it.The pressure gauge is hot when it has been in use.
- Disconnect the Connector from the Transmitter.
- Open the Clamp and remove the old Transmitter.
- Install the new Transmitter with the Clamp.Note: Do not forget the gasket.
- Connect the Connector at the Transmitter.

- Connector
- Transmitter
- Clamp
Steam Trap - Overhaul
| Equipment Status | Program Step |
- Remove the four Screw and take out the mechanism.
- Remove the two Screw and remove the Float ball.
- Check the Valve. If required, clean the valve, mechanism and housing.
- Assemble in the reverse order.

- Screw
- Screw
- Float ball
- Valve
- Gasket
CIP Flow Meter - Install the Wiring
| Equipment Status | Power must be turn OFF.
|
Hazardous voltage.The main power supply disconnector must be switched off and secured with a lock before starting any work on the wiring.Will shock, burn or cause death.
Risk of burns.Let the flow meter cool down before starting any work on it.The flow meter is hot when it has been in use.
- Insert the Cable into the Cable gland.
- Connect the Wire to the Terminal according to the illustration below.
- Tighten the Cable gland.
- Install the Cover with the Screw.
- Connect the power supply circuits.

- Cable
- Cable gland
- Wire
- Terminal
- Cover
- Screw
Functional Description
Valid for FestoThe supply unit supplies lubrication, water, and pneumatic air to the package section. It consists of sub groups according to the figure below.
- Pneumatic unit S1, valve ramp
- Pneumatic unit S2, valve ramp
- Hose installation - pneumatic
- Pipe work - lubrication
- Pipe work - water
- Cassette lubrication (water)
Valid for MecmanThe supply unit supplies lubrication, water, and pneumatic air to the package section. It consists of sub groups according to the figure below.
- Pneumatic unit S1, valve ramp
- Pneumatic unit S2, valve ramp
- Hose installation - pneumatic
- Pipe work - lubrication
- Pipe work - water
- Cassette lubrication (water)
Pipe-work Lubrication - Flow Chart

- Lever
- Draining pipe
- Valve
- Block 6-ways
- Block
- Junction block
- Junction block
- Valve and Metering valve
- Pressure switch
- Lubrication draining for bottom seal S1
- Lubrication draining for bottom seal S2
Pipe-work Lubrication - Drain
(The draining hose is connected to the Bottom Sealing house.)See the illustration above.- If an oil level is visible in the draining hose , put a vessel under the hose, open the valve, and drain the collected oil.
- Close the valveNote: Oil is regarded as hazardous waste and disposal should be done in accordance with local, state or national legislation.
Overview

- UV-lamp S1
- UV-lamp S2
- Pipe final folder S1
- Pipe UV-lamp S1
- Pipe return cooling unit
- Pipe final folder S2
- Pipe UV-lamp S2
- Pipe return cooling unit
Conveyor, Cassette Lubrication
Functional Description
The Cassette Lubrication is intended both for rinsing after a crash and for lubrication during production. During rinsing after a crash, minor product residues on the cassettes are flushed off. During production, the cassette links are lubricated with water.Drinking water, with no chemicals added is used, and a UV-lamp is sterilizing the water beforehand, for both machine sides. The system is automatically rinsed with Oxonia through the Valve during each disinfection phase.
- UV-lamp
- Valve
- Spraying nozzle
- Pressure reducing valve
If the alarm 73331 UV water cleaning lamp low intensity occurs, the UV-lamp and sensor must be checked and, if necessary, cleaned according to Cassette Lubrication - Clean UV-lamp and Sensor. If the problem is not resolved, check the UV-lamp assembly. Make sure that no water has reached the electrical connection.
- Pipes
- Flow control valve
- Flow control valve
Lubrication Water - Check
| Equipment Status | Program Step HEATING |
- Set the lubrication water pressure to 2 bar, by turning the Pressure reducing valve until the correct setting is shown.
- During maintenance work, close the Shut-off valve (drinking water) for incoming drinking water.

- Pressure reducing valve
- Shut-off valve (drinking water)
- Set the water flow from the Spraying nozzle, the Pipes, the Side feeder nozzle, and the Chain lubrication nozzle. The water must reach the cassettes above.Set the water flow with the flow regulators on the corresponding pipe work and the main Flow control valve.Note: If the water flow is not set to reach the cassettes, there will be damage on the conveyor. Damage on the conveyor might restrict the cassette movement.Note: The drinking water consumption should be set to approximately 140l/h.
- Activate the cassette flushing at the TPOP, one machine side at a time.Note: It is only possible to activate this function when there are no packages in the cassettes.

- Spraying nozzle
- Pipes
- Flow control valve
- Flow control valve
- Side feeder nozzle
- Chain lubrication nozzle
Cassette Lubrication - Clean UV-lamp and Sensor
| Equipment Status | Power must be turn OFF.
|
- Turn off the power.
- Close the Shut-off valve.
- Remove the Sensor connection.
- Remove the UV-sensor and drain the water.Note: There is a seal at the top connection of the UV-sensor but none at the bottom.
- Clean the Sensor glass with soap and a soft cloth. Put the UV-sensor back.Note: Do not forget the seal.
- Re-connect the Sensor connection.

- Shut-off valve
- Sensor connection
- UV-sensor
- Sensor glass
Risk of damage to the equipment.Do not touch the UV-lamp with your bare hands.Stains made by touching the UV-lamp with your bare hands will burn into the glass and cause premature failure.
Remove the Upper cap and disconnect the lamp.- Carefully lift the Lamp out.
- Remove the second Cap and the Ring.
- Carefully lift the Glass tube out.
Risk of damage to the equipment.Do not use an abrasive sponge to clean the tube.An abrasive sponge can damage the tube.
Clean the tube with soap and a soft cloth. Check that the inside of the tube is dry, and put the tube back.- Replace the O-ring and O-ring.
- Put the Ring back. Make sure that the Recess is facing downwards and against the O-ring.

(Reverse angle)
- Upper cap
- Lamp
- Cap
- Ring
- Glass tube
- Recess
- O-ring
- O-ring
- Spring
Note: Do not forget to put the Spring back inside the tube before fitting the lamp.- Put the Cap, the Lamp, and the Upper cap back. Tighten the Upper cap by hand.
- Open the Shut-off valve and check for leaks from:
Risk of damage to the equipment.Make sure that the
Glass tube is immersed in flowing water before it is lit.If the
Glass tube that contains the UV-lamp is not immersed in flowing water when the lamp is lit, the lamp will quickly overheat and burn out.
Turn on the power.
- Shut-off valve
- UV-sensor
- Upper cap
- Lamp
- Cap
- Spring
- Pressure reducing valve
- Control valve
Cassette Lubrication - Change UV-Lamp and O-Ring
| Equipment Status | Power must be turn OFF.
|
- Turn off the power.
- Close the Shut-off valve.

- Shut-off valve
Risk of damage to the equipment.Do not touch the UV-lamp with your bare hands.Stains that are made by touching the UV-lamp with your bare hands, will burn into the glass and cause premature failure.
Remove the Upper cap and disconnect the lamp.- Carefully remove the Lamp.
- Remove the second Cap and the Ring.
- Carefully remove the Glass tube.

(Reverse angle)
- Upper cap
- Lamp
- Cap
- Ring
- Glass tube
- O-ring
- Recess
Risk of damage to the equipment.Do not use an abrasive sponge to clean the tube.An abrasive sponge can damage the tube.
Clean the tube with soap and a soft cloth.Check that the inside of the tube is dry, and put the tube back.- Change the O-ring.
- Put the Ring back. Make sure that the Recess is facing downwards and against the O-ring.

(Reverse angle)
- Upper cap
- Lamp
- Cap
- Ring
- Glass tube
- O-ring
- Recess
Note: Do not forget to put the Spring back inside the tube before fitting the lamp.- Change the Lamp.
- Put the Cap, the Lamp, and the Upper cap back. Tighten the Upper cap by hand.
- Open the Shut-off valve and check for leaks from:
Risk of damage to the equipment.Make sure that the
Glass tube is immersed in flowing water before it is lit.If the
Glass tube that contains the UV-lamp is not immersed in flowing water when the lamp is lit, the lamp will quickly overheat and burn out.
Turn on the power.- Check the light intensity of the UV-lamp on the TPOP. The light intensity should be 50 or higher.

- Shut-off valve
- Upper cap
- Lamp
- Cap
- Spring
- Pressure reducing valve
- UV-sensor
- Control valve
Gas Dosing System (Optional Equipment)
Functional Description
Valid for Festo and MecmanNot all machines have the gas dosing system.Some products are affected by oxygen in the head-space of the package. Vitamins, colour, and taste can be affected. If the oxygen level is reduced, from the normal 21% to about 8 to 10%, the shelf life of the product can be increased considerably. The gas dosing system does that by replacing the oxygen with a substitute gas.- Gas at 4 to 6bar passes from the supply unit through a connection at the filling platform to a Valve block in the front of the machine. The valves switch between substitute gas and compressed air.
- A Proportional valve reduces the gas dosing pressure to the value that is set in the PLC-program. This is about 2.5bar during production.
- Valve block
- Proportional valve

- 5 micron filter
- 0.01 micron filter
- Fixed restriction
- Absolute filter
Two stations are fitted over the packages as follows:| Station 1 | Located before the product filling. |
| Station 2 | Located between the filling pipes and the bottom sealing. |
- When the gas dosing system is functioning but not in production there is a constant flow of compressed air through it. The airflow stops bacteria from entering the gas dosing system when the gas is turned off. This also reduces the gas consumption.
- As soon as a sleeve is fed from the cutting device into the conveyor (at production start), the valves switch from air to gas with a pulsed flow through the Pulse valve.

- Station 1
- Station 2
- Pulse valve
When the TTCU starts to clean the hygiene chamber the Valve, Valve and Drain Valve close and the Cleaning Solution Valve and the Valve opens. The Valve and Valve create a buffer that ensures that no build up of liquid reaches the Absolute filter. The valves stay in this configuration for all the TTCU cycles until the disinfection starts. In the disinfection cycle, the Valve opens and the area between the Valve and Valve is disinfected. After the hygiene chamber clean is complete the Cleaning Solution Valve closes and the Drain Valve opens to drain the remaining liquid and remains open during production. At this time the Valve and Valve opens and the Pulse valve starts to pulsate. Compressed air is then pushed through the system to push out any remaining fluids.
- Absolute filter
- Pulse valve
- Valve
- Valve
- Drain Valve
- Cleaning Solution Valve
- Valve
Nozzles Station No 2 - Set
| Equipment Status | Program Step |
- Make sure that the distance A between Station and the Bracket is equal on both sides of the Bracket.
- Make sure that Station and the Bracket are parallel to each other.
- Set distance B between the Nozzle and the Support, by adjusting the Nozzle.
- Station
- Bracket
- Nozzle
- Support
Pressure Guard (SDE1) - Set Switching Pressure
| Equipment Status | Program Step |
Note: This procedure is only needed if the pressure guard has been changed.For switching pressure setting “Out A” (factory setting: threshold comparator, “NO”):- Hold EDIT pressed down 3 seconds (SDE1 is then in “RUN mode”).
- Press EDIT 3 times (SP-field flashes).
- Set switching pressure to 2.0 bar with the UP/Down keys on SDE1.
- Hold EDIT pressed down 3 seconds (SDE1 is then in “RUN mode”).
Filter Unit - Change Filter Inserts
| Equipment Status | Program Step |
- Change the 5 micron Filter insert.
- Change the 0.01 micron Filter insert.

- Filter insert
- Filter insert
Sterile Filter - Change
| Equipment Status | Program Step |
Hygiene risk.Make sure that you do not contaminate the parts in any way as you work with them.These parts are not cleaned during a cleaning sequence.
Hygiene risk.Do not forget to put them back in the correct way after you have removed them.The
Sterile filter is very important for the hygiene in the system.
- Change the Sterile filter.

- Sterile filter
Butterfly Valve - Change Valve Seals
| Equipment Status | Program Step zero |
Risk of crushing and cutting.Release compressed air after use and disconnect the power supply before service.Do not stick your fingers through the valve ports if the actuator is supplied with compressed air.
Risk of crushing and cutting.Release compressed air after use and disconnect the power supply before service.Do not touch the coupling between the valve body and the actuator if compressed air is supplied to the actuator.
- Remove the Screw and the Nut.
- Remove the Actuator with the Bracket.

- Screw
- Nut
- Bracket
- Actuator
- Remove the Screw and the Nut.
- Split the Valve body.
- Remove the Bushing from the Valve disc.
- Remove the Seal ring from the Valve disc.Note: For valve sizes 25 mm to 38 mm and DN25 to DN40, it is recommended to remove the Seal ring with a special service tool (6-9611981090).
- Lubricate the Pin holes in the new Seal ring.Use USDA-H1 approved lubricants. See the following table.
| Unisilcon L641 |
| Paraliq GTE 703 |
| Molykote 111 (D) |

- Screw
- Nut
- Valve body
- Bushing
- Valve disc
- Seal ring
- Pin holes
- Assemble the new Seal ring to the Valve disc.Note: For the valve sizes 25 mm to 38 mm and DN25 to DN40, it is recommended to fit the Seal ring with a special service tool (6-9611981090).
- Assemble the Bushing to the Valve disc.
- Assemble the Valve disc between the Valve body.
- Assemble the Screw and the Nut.
- Rotate the Valve disc so that the valve is open before tightening the Screw and the Nut.
- Tighten the Screw and the Nut according to the torque table.
| Valve size | 25 mmDN25 | DN32 | 38 mmDN40 | 51 mmDN50 | 63.5 mmDN65 | 76 mmDN80 | 101.6 mmDN100 | DN125 | DN150 |
| Allen Key(LKB/LKB-2) | 5 mm | 5 mm | 5 mm | 6 mm | 6 mm | 6 mm | 8 mm | 8 mm | 8 mm |
| 0.2” | 0.2” | 0.2” | 0.24” | 0.24” | 0.24” | 0.3” | 0.3” | 0.3” |
| Recommended torque | 18 Nm | 18 Nm | 18 Nm | 20 Nm | 20 Nm | 20 Nm | 38 Nm | 38 Nm | 38 Nm |
| 13 lbf-ft | 13 lbf-ft | 13 lbf-ft | 15 lbf-ft | 15 lbf-ft | 15 lbf-ft | 28 lbf-ft | 28 lbf-ft | 28 lbf-ft |
- Assemble the Actuator with the Bracket. See Procedure Butterfly Valve - Assemble Actuator.

- Screw
- Nut
- Valve body
- Bushing
- Valve disc
- Seal ring
Butterfly Valve - Overhaul Actuator
| Equipment Status | Program Step zero |
| Special Equipment | Tool for LKLA TP No. 6-9611416791 |
| Consumables | Service kit TP No. 6-9611923021 |
Risk of personal injury.Keep the direction of the spring load facing away from you, when working with tensioned springs.The actuator is spring loaded and the springs are not caged.

- Tool for LKLA
- Press the End cap into the Air cylinder with the Tool for LKLA.
- Remove the Retaining ring.
- Carefully release the pressure on the End cap.
- Remove the End cap.

- Tool for LKLA
- End cap
- Air cylinder
- Retaining ring
- Remove the Piston.
- Remove the Spring and the Spring.
- Remove the Connex pin and the Coupling from the steam on the Rotating cylinder.
- Remove the Rotating cylinder.

- Piston
- Spring
- Spring
- Connex pin
- Coupling
- Rotating cylinder
- Change the following parts in the service kit:
- Assemble in the reverse order.

- O-ring
- O-ring
- O-ring
- Thrust bearing
- Needle bearing
- O-ring
- Needle bearing
Butterfly Valve - Assemble Actuator
| Equipment Status | Program Step zero |
Risk of crushing and cutting.Release compressed air after use and disconnect the power supply before service.Do not stick your fingers through the valve ports if the actuator is supplied with compressed air.
Risk of crushing and cutting.Release compressed air after use and disconnect the power supply before service.Do not touch the coupling between the valve body and the actuator if compressed air is supplied to the actuator.
Valve position and characteristic
Valid for: 3A
- V51Q1315 (NC)
- V51Q1316 (NC)
- V51Q1313 (NO)
- V51Q2315 (NC)
- V51Q2316 (NC)
- V51Q2313 (NO)
- V51Q0314 (NC)
Valve position and characteristic
Valid for: No 3A
- V51Q2268 (NC)
- V51Q1268 (NC)
- V51Q2269 (NO)
- V51Q1269 (NC)
- Turn the Valve disc to the designated position, NC, or NO. See Valve position and characteristic.

- Valve disc
- NC
- NO
- Assemble the Indicator to position NC or NO according to the NC or NO position of the valve disc.

- Indicator
- NC
- NO
- Assemble the Actuator and the Bracket to the Valve with the Screw and the Nut.
- Tighten the Screw and the Nut according to the torque table in Procedure Butterfly Valve - Change Valve Seals.

- Actuator
- Bracket
- Valve
- Screw
- Nut
Butterfly Valve - Change Ball Valve Seals
| Equipment Status | Program Step ZERO |
| Consumables | Alkali solution (Manual Cleaning) |
Remove Valve Groups
Risk of crushing and cutting.Release compressed air after use and disconnect the power supply before service.Do not stick your fingers through the valve ports if the actuator is supplied with compressed air.
Risk of crushing and cutting.Release compressed air after use and disconnect the power supply before service.Do not touch the coupling between the valve body and the actuator if compressed air is supplied to the actuator.
Heavy equipment.Handle the valve with care and make sure that you take precautions to handle the weight.The valve is heavy and can cause personal injuries and damage to equipment.
- Remove the Pneumatic hose.
- Remove the Cable.
- Remove the Valve by removing the Clamp and the Gasket, and place the valve on a clean suitable working area.Note: The other valves are removed in a similar way.

- Air coupling
- Silencer
- Valve
- Clamp
- Gasket
Overhaul Valve Groups
- With the valve in open position, remove three of the Screw and the Nut.
- Pull out the Valve body from the Valve end.Note: Be careful, not to damage or scratch the Ball.
- Close the Ball and remove the Seat ring, the Ball and the Seal.

- Screw
- Nut
- Valve body
- Valve end
- Ball
- Seat ring
- Seal
- Loose the Nut and remove the washers below it.
- Remove the Spindle and the Spindle gasket.
- Replace all parts included in the seal kit.
- Clean the remaining parts.
- Assemble in the reverse order. Tighten the Nut and the Screw.
- Check the function of the valve.

- Screw
- Nut
- Spindle
- Spindle gasket
Butterfly Valve - Change Diaphragm
| Equipment Status | Program Step ZERO |
Risk of crushing and cutting.Release compressed air after use and disconnect the power supply before service.Do not stick your fingers through the valve ports if the actuator is supplied with compressed air.
Risk of crushing and cutting.Release compressed air after use and disconnect the power supply before service.Do not touch the coupling between the valve body and the actuator if compressed air is supplied to the actuator.
Valve position and characteristic
Valid for: 3A
- V51Q1313 (NO)
- V51Q1316 (NC)
- V51Q1315 (NC)
- V51Q2315 (NC)
- V51Q2316 (NC)
- V51Q2313 (NO)
- V51Q0314 (NC)
Valve position and characteristic
Valid for: No 3A
- V51Q1269 (NC)
- V51Q2269 (NO)
- V51Q1268 (NC)
- V51Q2268 (NC)
Remove Actuator
- If the Actuator is in the closed position, move it to the open position.
- Remove the Bolt and the Actuator.
- Move the Actuator to the closed position.
Remove Diaphragm
- Unscrew the old Diaphragm and remove it.
- Clean the parts of the Actuator.
- Make sure that no parts of the Actuator are damaged.
- Replace any damaged parts.

- Actuator
- Bolt
- Diaphragm
Install Diaphragm
- Place the Compressor loosely on the actuator spindle and fit the Groove onto the Guide.
- Make sure that the Compressor fits closely in the Guide.
- Tightly screw the new Diaphragm into the Compressor.
- Make sure that the Diaphragm boss fits closely in the recesses of the Compressor.
- When you feel a clear resistance, turn the Diaphragm counter-clockwise until the bolt holes of the Diaphragm is in alignment with the bolt holes of the Actuator.
Install Actuator
- Move the Actuator to the open position.
- Put the Actuator back on the valve body.
- Install the Bolt and tighten them by hand.
- Move the Actuator to the closed position.
- Fully and evenly tighten the Bolt until the rubber has been compressed by 10-15%.

- Diaphragm
- Compressor
- spindle
- Groove
- Guide
- Diaphragm boss
Description
This chapter contains the maintenance procedures for the filling section. The functional description on page Functional Description provides a technical overview of parts of the filling section. For hygiene functions see page Hygiene Functions.Functional Description
IntroductionThe filling section has two main tasks:- to provide the right amount of filling product to the packages in the hygiene chamber.
- to perform and support hygiene functions of the filling machine (with the exception of external cleaning in the hygiene chamber cleaning and package disinfection).
The filling section is also the main supply distributor for granulate, drinking water, ice water, air, and gas (gas is only valid if the machine is equipped with the gas dosing system).For a functional description of the filling system, see page Filling System.For a functional description of the hygiene functions, see page Hygiene Functions.Filling System
Note: Distance filling is used on a ADY variant machine. Bottom up filling is used on a standard variant machine.Note: It is only possible to produce sweetened condensed milk on both production sides at the same time.The two production sides of the machine can produce two different products at the same time. Two separate 50 litre tanks for the filling product(s) enable the machine to fill two different products simultaneously and independently.The product enters the tank via a Valve. The valve keeps the product level in the tank relatively constant. Information about the current level is communicated from the Level probe via a signal from the PLC to the control unit in the Valve.Two filling pipes lead the product from the tank to the packages. A servo-assisted piston pump measure and portion the filling product from the package's open bottom end. For a functional description of the piston pump see Pump Units.
- Valve
- Actuator
- Positioner
- PLC
- Compressed air
- Nozzle
- Level probe
Hygiene Functions
The following list is a brief overview of the TT/3 filling machine hygiene functions:The machine program is configurated to perform cleaning in place, sterilisation in place, quick rinse, cleaning, and disinfection when started by the operator from the TPOP.For machine variant XH, the operator must activate, from the TPOP, the hydrogen peroxide system to run the machine with hydrogen peroxide.For machine variants AD, ADY, SD, ASCM, and Water, the machine is automatically run with hydrogen peroxide.For machines variants XH, 3A and XHIC, a short automatic purge is performed every four hours during production.Cleaning of the Filling System (Cleaning In Place, CIP)
The CIP cleans the filling system by using the diary cleaning supplies systems or by using a separate unit called ALCIP. The purpose of the CIP is to ensure that there are no residual product in the filling system nor in their connections. The program is performed in many steps. See the flow charts and sequence diagram for more information on the CIP steps. The flow charts and the sequence diagram are laminated documents. The sequence diagrams can also be seen in Chapter General. For more information see also the OM.Sterilisation of the Filling System (Sterilisation In Place, SIP)
The purpose of the SIP is to reduce the number of bacteria in the filling system. This is done by the SIP and must be preceded by a complete CIP. - Heating
- Steam sterilisation 122°C, 20 minutes
- Cooling
- Pressure balance. The purpose of the last step is to balance the pressure and cool the pipes in order to make production start possible.
See the flow charts and sequence diagram for more information on the SIP steps. The flow charts and the sequence diagram are laminated documents. The sequence diagrams can also be seen in Chapter General. For more information see also the OM.Quick Rinse of the Filling System (QR Optional)
The purpose of the QR is to rinse out product left in the filling system at the time for product change.The QR option differ from product to product and must be evaluated and defined. The result of a QR is a product contact surfaces that are visually clean. The principle of the QR program is to open up paths of the product contact surfaces in the filling system. 2 to 3 paths are used and repeated a number of times.It is site responsibility to evaluate an define how many times the water rinse sequences should be repeated. The total time needed for a QR is the time that the water (at specified quality) must be supplied to the TT/3 .Cleaning and Disinfection of the Hygiene Chamber
The purpose of the cleaning and disinfection is to remove residual product and to reduce the number of bacteria in the area where the packages are filled and sealed.This is performed by a separate unit, the Tetra Top Cleaning Unit (TTCU). For more information on the TTCU see Chapter Tetra Top Cleaning Unit. See also the OM.Clean Air System
| High Efficiency Particulate Air (HEPA) flows from cabinets and units to the: |
| • | Hygiene chamber. The HEPA cabinet for the Package Section (PS) provides the hygiene chamber with a defined flow of filtered HEPA. Here, the purpose of HEPA is to prevent contamination from the surrounding environment during the filling and sealing processes. The filtered HEPA enters the hygiene chamber where the packages enter chamber and above the bottom sealing. |
| • | Hydrogen peroxide (H2O2) reducer. The H2O2 reducer has outlets above the cassettes in the hygiene chamber as hot filtered HEPA is used for removing the H2O2 residue in the packages before filling. |
| • | Tank breathing and cleaning boxes. The filtered HEPA from the HEPA cabinet for the Filling Section (FS) prevents the surrounding air from entering the product tanks during filling. The excess air from the tanks is directed to the cleaning boxes where it is distributed around the filling pipes. |
| • | Valid for: Hygiene level UHHLid Forming Unit (LFU). The HEPA cabinet for LFU provides a defined flow of filtered HEPA over the LFU. Here, the purpose of HEPA is to prevent contamination from the surrounding environment. The HEPA filter is in the filter housing above the LFU. |
| • | Valid for: Hygiene level UHHValid for: Equipment with CAUCap Application Unit (CAU). The HEPA cabinet for CAU provides a defined flow of filtered HEPA over the CAU to prevent contamination from the surrounding environment. The HEPA filter is in the filter housing above the CAU. |

The illustration shows the machine variant Water.
Air Unit
Overview
A: Side 1B: Side 2
HEPA Unit, PS - Change Air Inlet Filter
| Equipment Status | Program Step |
- Change the air inlet filter (1).
- Step the machine up to tank filling. Remain in tank filling for 5 minutes.

- Inlet filter
HEPA Unit, PS - Change Pre-filter
| Equipment Status | Program Step |
| Special Equipment | Soft cloth |
| Consumables | Detergent Code D Disinfectant Code G1 |
- Loosen the locking devices and remove the Hatch.
- Remove the Nut and washer, the Frame, and the Pre-filter.
- Use a cloth rinsed in a mixture of water and detergent, squeeze it properly and clean manually:
- The walls of the HEPA cabinet.
- The inside of the Hatch.
- Apply disinfectant on the surfaces mentioned above, by using a clean cloth sprayed with disinfectant.

- Hatch
- Nut and washer
- Frame
- Pre-filter
Risk of damaging equipment.Be careful when handling and installing the filter as they may easily become deformed. Even small damages will effect the filtration. Install the filter correctly.
Put in the new Pre-filter.Note: Make sure that the gasket of the filter is facing downwards.- Assemble the Frame and tighten the nuts (2) to the mechanical stop.
- Fit the Hatch and close the locking devices.
- Step the machine up to tank filling. Remain in tank filling for 5 minutes.

- Hatch
- Nut and washer
- Frame
- Pre-filter
HEPA Unit, PS - Change HEPA Filter
| Equipment Status | Program Step step zero |
| Special Equipment | Soft cloth |
| Consumables | Detergent Code D Disinfectant Code G1 |
- Loosen the locking devices and remove the Hatch.
- Remove the Wing nut and the Plate and remove the HEPA filter.
- Use a cloth rinsed in a mixture of water and detergent. Squeeze it properly and clean the following manually:
- The walls of the HEPA cabinet.
- The inside of the Hatch.
- Apply disinfectant on the surfaces mentioned above, by using a clean cloth sprayed with disinfectant.

- Hatch
- Wing nut
- Plate
- HEPA filter
Risk of damaging equipment.Be careful when handling and installing the filter as they may easily become deformed. Even small damage will affect the filtration. Install the filter correctly.
Install the new HEPA filter.Note: Make sure that the gasket of the filter is facing downward.- Mount the Plate and the Wing nut.
- Fit the Hatch and close the locking devices.
- Step the machine up to tank filling. Remain in tank filling for five minutes.

- Hatch
- Wing nut
- Plate
- HEPA filter
Peroxide Reducer - Change Pre-filter
| Equipment Status | Program Step |
- Remove the Wing nut and the Washer.
- Remove the Cover.
- Change the Pre-filter insert.
- Assemble the Cover. Place the Washer and tighten the Wing nut.
- Step the machine up to TANK FILLING. Remain in TANK FILLING for 5 minutes.

- Wing nut
- Washer
- Cover
- Pre-filter insert
Peroxide Reducer - Change HEPA Filter
| Equipment Status | Program Step step zero |
| Special Equipment | Soft cloth |
| Consumables | Detergent Code D Disinfectant Code G1 |
- Remove the Nut and the Washer.
- Remove the Lid.
- Remove the Gasket.
- Remove HEPA filter insert.
- Use a cloth rinsed in a mixture of water and detergent. Squeeze it properly and clean the following manually:
- Apply disinfectant on the surfaces mentioned above, by using a clean cloth sprayed with disinfectant.

- Nut
- Washer
- Lid
- Gasket
- HEPA filter insert
- Filter housing
Risk of damaging equipment.Be careful when handling and installing the filter as it may easily become deformed. Even small damage will affect the filtration. Install the filter correctly.
Install the new HEPA-filter insert.Note: Make sure that the gasket of the filter is facing downward.- Place the Gasket on the edge of the Filter housing. Assemble the Lid, the Washer, and the wing Nut. Tighten the wing Nut crosswise.
- Step the machine up to TANK FILLING. Remain in TANK FILLING for five minutes.

- Nut
- Washer
- Lid
- Gasket
- HEPA-filter insert
- Filter housing
HEPA Unit, FS - Change Pre-filter
| Equipment Status | Program Step step zero |
If the pre-filter or the HEPA filters are changed on a machine equipped with HEPA filter monitoring, redo the procedures that handle the alarm limit calculations on the HEPA filters. See the Commissioning and Validation Plan Manual (CVP), Procedure 3.5.2-19 Filling Section HEPA Air During Heating: Low Pressure Side 1 to 3.5.2-27 Filling Section HEPA Filter V68V1245 and V68V2245: Set Alarm Levels.- Remove the Wing nut and the Washer.
- Remove the Cover.
- Change the Pre-filter insert.
- Assemble the Cover. Place the Washer and tighten the Wing nut.
- Step the machine up to TANK FILLING. Remain in TANK FILLING for 5 minutes.

- Wing nut
- Washer
- Cover
- Pre-filter insert
HEPA Unit, FS - Change HEPA Filter
| Equipment Status | Program Step step zero |
| Special Equipment | Soft cloth |
| Consumables | Detergent Code D Disinfectant Code G1 |
If the pre-filter or the HEPA filters are changed on a machine equipped with HEPA filter monitoring, redo the procedures that handle the alarm limit calculations on the HEPA filters. See the Commissioning and Validation Plan Manual (CVP), Procedure 3.5.2-19 Filling Section HEPA Air During Heating: Low Pressure Side 1 to 3.5.2-27 Filling Section HEPA Filter V68V1245 and V68V2245: Set Alarm Levels.- Loosen the locking devices and remove the Hatch.
- Remove the Wing nut, the Plate and remove the HEPA filter.
- Use a cloth rinsed in a mixture of water and detergent, squeeze it properly and clean manually:
- The walls of the HEPA cabinet.
- The inside of the Hatch.
- Apply disinfectant on the surfaces mentioned above, by using a clean cloth sprayed with disinfectant.

- Hatch
- Wing nut
- Plate
- HEPA filter
Risk of damaging equipmentBe careful when handling and installing the filter as they may easily become deformed. Even small damages will effect the filtration. Install the filer correctly.
Install the new HEPA filter.Note: Make sure that the pre-filter for UV ventilation is not used by mistake.Note: Make sure that the gasket of the filter is facing inwards.- Mount the Plate and the Wing nut.
- Fit the Hatch and close the locking devices.
- Step up the machine to tank filling. Remain in tank filling for 5 minutes.

- Hatch
- Wing nut
- Plate
- HEPA filter
HEPA Unit, FS - Set Pressure Transmitter
| Equipment Status | Power must be turn OFF.
|
- Set the Switch according to the illustration below.

- Switch
Pneumatic Unit
Overview
Side 1Side 2
| 1 Regulator, V60R1283 | 6 Regulator, V60R2283 |
| 2 Regulator, V60R1286 | 7 Regulator, V60R2286 |
| 3 Regulator, V60R1284 | 8 Regulator, V60R2284 |
| 4 Regulator, V60R1285 | 9 Regulator, V60R2285 |
| 5 Regulator, V60R1287 | 10 Regulator, V60R2287 |
Pneumatic Unit - Basic Setting
| Equipment Status | Program Step |
Valid for Festo
Set the pressure according to the table below. Turn the pressure regulators (1) to (10) and check the pressure on the gauge.
Side 1Side 2
| Pos in illustration | Machine function | Base Pressure kPa (bar) | Midi, Mini, Micro,Pressure kPa (bar) | Mini ADYPressure kPa (bar) |
| 1 (V60R1283) | Resuction Side 1 - Production | 50 (0.5) | 50 (0.5) | 50 (0.5) |
| 2 (V60R1286) | UPV Side 1 - Closed | 250 (2.5) | 250 (2.5) | 550 (5.5) |
| 3 (V60R1284) | Resuction Side 1 - CIP | 400 (4.0) | 400 (4.0) | 400 (4.0) |
| 4 (V60R1285) | UPV Side 1 - Open | 550 (5.5) | 550 (5.5) | 550 (5.5) |
| 5 (V60R1287) | UPV Side 1 - Open, Production | 550 (5.5) | 200 (2.0) | 550 (5.5) |
| 6 (V60R2283) | Resuction Side 2 - Production | 50 (0.5) | 50 (0.5) | 50 (0.5) |
| 7 (V60R2286) | UPV Side 2 - Closed | 250 (2.5) | 250 (2.5) | 550 (5.5) |
| 8 (V60R2284) | Resuction Side 2 - CIP | 400 (4.0) | 400 (4.0) | 400 (4.0) |
| 9 (V60R2285) | UPV Side 2 - Open | 550 (5.5) | 550 (5.5) | 550 (5.5) |
| 10 (V60R2287) | UPV Side 2 - Open, Production | 550 (5.5) | 200 (2.0) | 550 (5.5) |
Valid for Mecman
Set the pressure according to the table below. Turn the pressure regulator (1) to (10) and check the pressure on the gauge.
Side 1Side 2
| Pos in illustration | Machine function | Base Pressure kPa (bar) | Midi, Mini, Micro,Pressure kPa (bar) | Mini ADYPressure kPa (bar) |
| 1 (V60R1283) | Resuction Side 1 - Production | 50 (0.5) | 50 (0.5) | 50 (0.5) |
| 2 (V60R1286) | UPV Side 1 - Closed | 250 (2.5) | 250 (2.5) | 550 (5.5) |
| 3 (V60R1284) | Resuction Side 1 - CIP | 400 (4.0) | 400 (4.0) | 400 (4.0) |
| 4 (V60R1285) | UPV Side 1 - Open | 550 (5.5) | 550 (5.5) | 550 (5.5) |
| 5 (V60R1287) | UPV Side 1 - Open, Production | 550 (5.5) | 200 (2.0) | 550 (5.5) |
| 6 (V60R2283) | Resuction Side 2 - Production | 50 (0.5) | 50 (0.5) | 50 (0.5) |
| 7 (V60R2286) | UPV Side 2 - Closed | 250 (2.5) | 250 (2.5) | 550 (5.5) |
| 8 (V60R2284) | Resuction Side 2 - CIP | 400 (4.0) | 400 (4.0) | 400 (4.0) |
| 9 (V60R2285) | UPV Side 2 - Open | 550 (5.5) | 550 (5.5) | 550 (5.5) |
| 10 (V60R2287) | UPV Side 2 - Open, Production | 550 (5.5) | 200 (2.0) | 550 (5.5) |
Ventilation UV-lamp - Change Filter
| Equipment Status | Program Step |
Hot parts.The ventilation tubes for the UV -lamp can be hot and can cause burn damages. Use caution when working near the UV -lamp ventilation.
- Remove the Nut.
- Remove the Plate and the Filter.
- Install the new Filter.Note: Make sure that the HEPA filter for HEPA unit FS is not used by mistake.
- Mount the Plate and Nut.

- Nut
- Plate
- Filter
LFU HEPA Cabinet - Change Air Inlet Filter
| Equipment Status | Program Step |
- Change the air Inlet filter.
- Step the machine up to TANK FILLING. Remain in TANK FILLING for 5 minutes.

- Inlet filter
LFU HEPA Cabinet - Change Pre-filter
| Equipment Status | Program Step |
| Special Equipment | Soft cloth |
| Consumables | Detergent Code D Disinfectant Code G1 |
- Loosen the locking devices and remove the Hatch.
- Remove the Nut and washer, the Frame and the Pre-filter.
- Use a cloth rinsed in a mixture of water and detergent, squeeze it properly and clean manually:
- The walls of the HEPA cabinet.
- The inside of the Hatch.
- Apply disinfectant on the surfaces mentioned above, by using a clean cloth sprayed with disinfectant.

- Hatch
- Nut and washer
- Frame
- Pre-filter
Risk of damaging equipment.Be careful when handling and installing the filter as they may easily become deformed. Even small damages will effect the filtration. Install the filter correctly.
Put in the new Pre-filter.Note: Make sure that the gasket of the filter is facing downwards.- Assemble the Frame and tighten the Nut and washer to the mechanical stop.
- Fit the Hatch and close the locking devices.
- Step the machine up to tank filling. Remain in tank filling for 5 minutes.

- Hatch
- Nut and washer
- Frame
- Pre-filter
Measures Particles in HEPA System
HEPA Unit - Evaluation
- Measure the particles in the HEPA air according to the procedures below:
- Run eight measuring cycles to make sure that the values are stable. Use the values from the last three stable measurements.
- Make sure that none of the measured values are higher than 100, which means less than 100 particles/ft3 with the size 0.5 µm. Particles bigger than 0,5 µm is not allowed.
- If any of the values (from the stable measurements) are higher then the allowed value, check that part of the clean air system and make sure that:
- the HEPA-filter is intact.
- the HEPA-filter gasket is intact.
- the HEPA-filter is assembled correctly.
- all the clamps in the HEPA-system and if necessary tighten the clamps.
- there are no holes in any hose or hose connection.
HEPA Unit LFU - Particle Measurements
| Equipment Status | Program Step PREHEATING |
| Special Equipment | Particle Counter 3348051-0100 |
Risk of damaging equipmentBe careful when placing the nozzle inside the filter housing.The filter may easily become deformed. Even small damages will affect the filtration.
- Read instructions in HEPA Unit - Evaluation before you start.
- Carefully insert the Measuring hose two centimeters inside the HEPA channel in Measuring area.
- Program the particle counter to measure 8 cycles in a row, see HEPA Unit - Set Particle Counter.
- Start the measurement by pressing the particle counter START button.
- Close the doors to the Carton Section and the Hygiene Chamber.
- Store the record of particle count data.
- Move the Measuring hose to the next measuring area and repeat item Reference to Reference for all five measuring areas.
- Remove the Measuring hose.

- Measuring hose
- HEPA channel
- Measuring area
- Measuring area
- Measuring area
- Measuring area
- Measuring area
HEPA Unit, PS - Particle Measurements Hygiene Chamber
| Equipment Status | Program Step PREHEATING |
| Special Equipment | Particle counter 3348051-0100 |
- Read instructions in HEPA Unit - Evaluation before you start.
- Pull the particle counter Measuring hose into the hygiene chamber by Carton Section.

- Measuring hose
- Remove the Screw.
- Remove the HEPA sheet / HEPA box.
- Assemble the Measuring hose inside the HEPA channel. Make sure that the end of the Measuring hose is not touching the wall inside the HEPA channel.
- Program the particle counter to measure 8 cycles in a row, see HEPA Unit - Set Particle Counter.
- Close the doors to the Hygiene Chamber.
- Start the measurement by pressing the particle counter START button.
- Store the record of particle count data.
- Remove the Measuring hose.

USA/Canada

Other countries
- Screw
- HEPA sheet / HEPA box
- HEPA channel
HEPA Unit, PS - Particle Measurements Peroxide Reducer
| Equipment Status | Program Step PREHEATING |
| Special Equipment | Particle counter 3348051-0100 |
Incorrect values.Make sure that the hygiene chamber is clean and dry.Dust or droplets in the hygiene chamber will affect the measurements negatively.
Read instructions in HEPA Unit - Evaluation before you start.- Assemble the Measuring device 3348050-0000 at the outlet of the Peroxide reducer nozzle.
- Program the particle counter to measure 8 cycles in a row, see HEPA Unit - Set Particle Counter.
- Close the doors to the Hygiene Chamber.
- Start the measurement by pressing the particle counter START button.
- Store the record of particle count data.
- Remove the Measuring device 3348050-0000.

- Measuring device 3348050-0000
- Peroxide reducer nozzle
HEPA Unit, PS - Particle Measurements Cleaning Box
| Equipment Status | Program Step PREHEATING |
| Special Equipment | Particle counter 3348051-0100 |
Incorrect values.Make sure that the filling system is clean and dry.Dust or droplets in the filling system will affect the measurements negatively.
- Read instructions in HEPA Unit - Evaluation before you start.
- Move the particle counter Measuring hose to the Cleaning box.
- Attach the Measuring hose with a piece of tape to one of the Cassette. The Measuring hose must be about one centimeter into the Cleaning box.Note: The opening of the Measuring hose must not touch the wall of the Cleaning box.
- Program the particle counter to measure 8 cycles in a row, see HEPA Unit - Set Particle Counter.
- Close the doors to the Hygiene Chamber.
- Start the measurement by pressing the particle counter START button.
- Run a total of eight measuring cycles.
- Store the record of the particle count data.

- Measuring hose
- Cleaning box
- Cassette
HEPA Unit CAU - Particle Measurements
| Equipment Status | Program Step PREHEATING |
| Special Equipment | Particle Counter 3348051-0100 |
Risk of damaging equipmentBe careful when placing the nozzle inside the filter housing.The filter may easily become deformed. Even small damages will affect the filtration.
- Read instructions in HEPA Unit - Evaluation before you start.
- Carefully insert the measuring hose two centimetres inside the HEPA channel in Measuring area.
- Program the particle counter to measure 8 cycles in a row, see HEPA Unit - Set Particle Counter.
- Start the measurement by pressing the particle counter START button.
- Close the doors to the Carton Section, the CAU, and the Hygiene Chamber.
- Run a total of eight measuring cycles.
- Store the record of particle count data.
- Move the measuring hose to the next measuring area and repeat item Reference to Reference for all three measuring areas.
- Remove the measuring hose.

- Measuring area
- Measuring area
- Measuring area
HEPA Unit - Set Particle Counter
| Equipment Status | Program Step PREHEATING |
| Special Equipment | Particle Counter 3348051-0100 |
- Push the CFG button on the touch screen to set the particle counter.

CFG button
- Check that the particle counter is set according to picture. When OK, press the Back button.

Back button
- Press the Sample button.

Sample button
- Check that the particle counter is set according to the table.
| Cycles: | 008 |
| Delay: | 00:00:05 |
| Hold: | 00:00:15 |
| Sample: | 00:01:00 |
| Volume: | 1.000 |
- Check that the ft3 is selected.
- Press the Back button.

ft3Back button
- Press the Setting button.

Setting button
- Check that the Auto button, Diff button, Norm button, and ft3 button are according to the picture.
- Press the Back button.

Auto buttonDiff buttonNorm buttonft3 buttonBack button
HEPA Fan
The HEPA fans in the HEPA units should always run to maintain a continuous air flow through the filters. To ensure this, keep the machine supplied with power, even when it is not in production.HEPA Fan - Procedure for Short Stops (<1 hour)
If a HEPA fan stops for less than one hour, there is no action.HEPA Fan - Procedure for Medium Stops (1-48 hours)
| Equipment Status | Program Step |
If a HEPA fan stops for a period of more than one but less than 48 hours- make sure that there is power supply to the HEPA fans.
- step up the machine to tank filling.
- keep the machine in tank filling for 30 minutes. Then the machine is ready to use.
HEPA Fan - Procedure for Long Stops (>48 hours)
| Equipment Status | Program Step STEP ZERO |
| Special Equipment | Alkali solution Isopropanol 70% Soft cloth |
If a HEPA fan stops for more than 48 hours- remove all HEPA filters.
- clean the HEPA cabinet and all the HEPA ducts. Use a soft cloth and alcoholic solution (Isopropanol 70%). See Chemicals for Cleaning and Disinfection.
- install new HEPA filters. Follow these procedures:
- measure particles in the HEPA air. Follow these procedures:
Functional Description
The filling nozzles are fitted on the filling tubes in the cleaning boxes, as shown in the illustration below.
- Cleaning box
- Filling tube
- Nozzle
Functional Description
The Filling pipe are located in the Cleaning box as shown in the illustration below.
- Cleaning box
- Filling pipe
Cleaning Box - Change Nozzle
| Equipment Status | Program Step |
- Remove the Nozzle by pulling it downwards.
- Fit the new Nozzle onto the Filling tube, making sure that the step on the Nozzle is securely fitted onto the groove of the Filling tube.
- Gently pull the Nozzle to make sure that it is firmly secured onto the Filling tube.

- Cleaning box
- Filling tube
- Nozzle
Cleaning Box - Change Nozzle
| Equipment Status | Program Step |
| Consumables | Cleaning Detergents Soft cloth |
- Turn the locking ring right to the gap.
- Push the ring upwards, turn it to he left and remove the nozzle.
- Clean the filling tube and nozzle with disinfection liquid. This will lubricate the touching surfaces of the nozzle and the locking ring, that otherwise would easily stick to each other.
- Recommended chemical for manual disinfection, see section Cleaning Detergents in the OM (Operation Manual).
- Fit the new nozzle onto the filling tube. Make sure that the step of the nozzle enters into the groove of the filling tube.
- Turn the locking ring to the gap, pull the ring downwards and turn the ring until it snaps into position.
- Pull the nozzle gently to make sure that the nozzle is firmly secured onto the filling tube.
Cleaning Box - Change Piston
| Equipment Status | Power must be turn OFF.
|
- Disconnect the servo cables and remove the servo motor. See Procedure Servo Motor - Change step a) - c).
- Put the Cover on the tip of the Filling pipe.

- Cover
- Filling pipe
- Disconnect the Pipe by removing the Clamp.

- Product pipe
- Clamp
- Remove the Clamp.
- Gently pull the Servo motor up and push it to the side to disengage the Servo motor from the Shaft.
- Check the Knob. If the Knob is damaged, change the Knob.

- Clamp
- Servo motor
- Shaft
- Knob
- Remove the four M8 Screw and Washer.
- Lift the Filling pipe up and bring it out of the machine.

- Filling pipe
- Screw
- Washer
- Remove the Filling pipe by removing the Screw.

- Filling pipe
- Screw
- Remove the Piston with a wrench, while holding the Shaft with another wrench.
- Remove the Gasket from the Shaft.
- Assemble a new Gasket onto the Shaft.

- Piston
- Shaft
- Gasket
- Assemble the new Piston to the Shaft by hand.Tighten the Piston to the Mechanical stop, to ensure correct compression of the Gasket.
- Assemble the filling pipe in the reverse order. Check that the servo motor is in the right position.

- Piston
- Shaft
- Gasket
- Mechanical stop
Cleaning Box - Change Bushings and Scraper Ring
| Equipment Status | Power must be turn OFF.
|
| Special Equipment | Female Bearing Replacement Kit TP No. 90606-8299 Service tool TP No. 3414407-0000 Service tool TP No. 3414409-0000 Service tool TP No. 3414410-0000 Lifting tool TP No. 90606-8294 |
- Pull down and remove the Shaft.
- Tap upwards diagonally in sequence and remove the Scraper ring with 3414409-0000.
- Tap upwards and remove Bushing with 3414410-0000.
- Assemble Bushing and Scraper ring with the tool number 3414407-0000.

- Shaft
- Scraper ring
- Bushing
Cleaning Box - Change Knob
| Equipment Status | Power must be turn OFF.
|
See Procedure Servo Motor - Change.Mechanism Cleaning Lid
Risk of crushing and cutting.Use caution when working with the cleaning lid mechanism.The cylinders in the cleaning lid mechanism can move even when they are not supplied with compressed air.
Mechanism Cleaning Lid - Check Cleaning Lid Gasket
| Equipment Status | Program Step |
- During CIP (or SIP), check that there is no leakage of cleaning fluid between the Cleaning lid and the Cleaning box.
- Check that the cleaning mechanism moves smoothly, during the change from production position to cleaning position, and that there is no air leakage from pneumatic connections and cylinders.

Cleaning positionProduction position
- Cleaning lid
- Cleaning box
- Gasket
Mechanism Cleaning Lid - Set
| Equipment Status | Program Step |
| Special Equipment | Hose Feeler gauge |
- Loosen the Screw and remove the Hood.
- Manually lift the Cleaning lid rod and release the locking mechanism on the Air cylinder by turning the knob (5) counter clockwise.
- Lower the Cleaning lid rod.
- Loosen the four Screw.
- Loosen the Screw securing the Angle bracket to the tank bracket (not shown in the illustration).
- Remove the pneumatic hoses marked according to the table below.
| Hose marking |
| V61W1250 (S1) | V61W2250 (S2) |
| V61W1249 (S1) | V61W2249 (S2) |

- Screw
- Hood
- Cleaning lid rod
- Air cylinder
- Knob
- Screw
- Screw
- Angle bracket
- Lift the cleaning lid unit by turning the Bolt and remove the Shim.
- Lower the unit by turning the Bolt so that it rests on the surface of the upper outer pipe Bracket where the Shim used to be.
- Turn the cleaning lid unit to the cleaning position.
- Manually lift the Cleaning lid rod and move the Wedge to its front position.
Risk of crushing.Be careful when activating the cylinder.The air cylinder will move if the it is activated by compressed air.
Use compressed air to lift the Cleaning lid in position for cleaning, the gaskets seals towards the edge of the Cleaning box. Connect compressed air to the pneumatic Hose according to the table below.| Hose marking |
| V61W1251 (S1) |
| V61W2251 (S1) |

Cleaning position
- Cleaning lid rod
- Bolt
- Shim
- Bracket
- Wedge
- Cleaning lid
- Cleaning box
- Hose
- Measure the distance A, between the Wedge and the Upper roll, and make a note of it.
- Move the Wedge to its rear position, remove the air pressure, and lower the cleaning lids.
- Lift the unit by turning the Bolt. Add Shim between the Plate and the upper outer pipe Bracket until B is reached.
- Lower the unit and tighten the Screw.

B (mm) = A + 1.4
- Screw
- Bolt
- Shim
- Bracket
- Wedge
- Upper roll
- Plate
- Make sure that the Cleaning lid and the Cleaning box are parallel and secure the Angle bracket onto the tank bracket.
- Turn the cleaning lid to the production position, manually lift the Cleaning lid rod to the upper position and attach the locking device on the Air cylinder by turning the Knob clockwise.Note: The cleaning lid shaft, should move easily during the manual lifting. If necessary adjust the Angle bracket.
- Set the throttle valves, see procedure Mechanism Cleaning Lid - Basic Setting Throttle Valves on page Mechanism Cleaning Lid - Basic Setting Throttle Valves.
- Connect the pneumatic hoses.
- Assemble the Hood and tighten the Screw.
- Check the cleaning lid mechanism, choose program step cleaning in place on the TPOP.
- When the cleaning lid is in the cleaning position, abort the program step by pressing the off button.

A = Cleaning positionB = Production position
- Screw
- Hood
- Cleaning lid rod
- Air cylinder
- Knob
- Angle bracket
- Cleaning lid
- Cleaning box
Mechanism Cleaning Lid - Basic Setting Throttle Valves
| Equipment Status | Program Step |
Turning cylinder (1).
Turn the Throttle valve clockwise to close position, then open by turning them 3 times counter clockwise.Up/down cylinder (4).
Turn the up position Throttle valve clockwise to close position, then open by turning it 6 times counter clockwise. Turn the down the position Throttle valve clockwise to close position, then open by turning it 4 times counter clockwise.Closing cylinder (8).
Turn the Throttle valve for -position, and the Throttle valve for +position clockwise to close position, then open by turning them 6 times counter clockwise.
- Turning cylinder
- Throttle valve
- Throttle valve
- Up/down cylinder
- Throttle valve
- Throttle valve
- Throttle valve
- Closing cylinder
Mechanism Cleaning Lid - Change Cleaning Lid Gasket
| Equipment Status | Program Step |
- Prise with a screwdriver (or similar) to remove the Gasket.Note: There is a tight fit between the Gasket and the Lid.
- Use a screwdriver (or similar) to prise during the installation of a new Gasket.

- Gasket
- Lid
Tank Unit
Overview
Left image: Side 1. Right image: Side 2
Overview

Side 1. The tank drain valve (25) and the drain valve (26) are included in the pump unit. Not valid for Variant ADY.

Side 1. The tank drain valve (25) and the drain valve (26) are included in the pump unit. Valid for Variant ADY.
| Pos | Description | Function No. | Pos | Description | Function No. |
| 1 | Steam trap valve | V61M1278 | 15 | Steam trap valve HEPA vent FS | V61M1275 |
| 2 | Cleaning box valve | V61M1273 | 16 | Steam trap | V61B1221 |
| 3 | Steam / compressed air / security valve (NO) | V61M1283 | 17 | Steam trap | V61V1268 |
| 4 | Steam trap valve | V61M1279 | 18 | Steam trap | V61V1269 |
| 5 | Tank vent valve | V60M1278 | 19 | Steam trap | V61V1266 |
| 6 | Steam purge valve | V61M1276 | 20 | Steam trap | V61V1267 |
| 7 | Tank compressed air valve | V60M1277 | 21 | Air sensor | V60B1212 |
| 8 | Compressed air valve | V61M1277 | 22 | Pressure gauge | A66B1217 |
| 9 | Product valve | V60M1255 | 23 | Pressure relief valve | V61M1281 |
| 10 | CIP/ HEPA valve | V61M1270 | 24 | Steam purge valve | V61M1280 |
| 11 | Steam in valve | V61M1282 | 25 | Tank drain valve | V60M1279 |
| 12 | Tank clean valve | V61M1291 | 26 | Drain valve | V60M1280 |
| 13 | Valve HEPA air to product tank / cleaning box | V68M1256 | 27 | Positioning unit | V61K1284 |
| 14 | Regulating valve tank level(Not valid for Variant ADY) | V60M1257 | | | |
| 14* | Tank clean valve (Valid for Variant ADY) | V60M1334 | | | |

Side 2. The tank drain valve (52) and the drain valve (53) are included in the pump unit. Not valid for Variant ADY.

Side 2. The tank drain valve (52) and the drain valve (53) are included in the pump unit. Valid for Variant ADY.
| Pos | Description | Function No. | Pos | Description | Function No. |
| 28 | Steam trap valve | V61M2278 | 41 | Valve HEPA air to product tank / cleaning box | V60M2257 |
| 29 | Cleaning box valve | V61M2273 | 42 | Steam trap valve HEPA vent FS | V61M2275 |
| 30 | Steam / compressed air / security valve (NO) | V61M1283 | 43 | Steam trap | V61B2221 |
| 31 | Compressed air valve | V61M2279 | 44 | Steam trap | V61V2268 |
| 32 | Steam purge valve | V60M2278 | 45 | Steam trap | V61V2269 |
| 33 | Steam trap valve | V61M2276 | 46 | Steam trap | V61V2266 |
| 34 | Tank compressed air valve | V60M2277 | 47 | Steam trap | V61V2267 |
| 35 | Tank vent valve | V61M2277 | 48 | Pressure gauge | V60B2212 |
| 36 | CIP/ HEPA valve | V60M2255 | 49 | Air sensor | A66B2217 |
| 37 | Product valve | V61M2270 | 50 | Steam purge valve | V61M2281 |
| 38 | Tank clean valve | V61M2282 | 51 | Pressure relief valve | V61M2280 |
| 39 | Regulator valve, tank level(Not valid for Variant ADY) | V61M2291 | 52 | Tank drain valve | V60M2279 |
| 39* | Tank clean valve (Valid for Variant ADY) | V60M2334 | 53 | Drain valve | V60M2280 |
| 40 | Steam in valve | V68M2256 | 54 | Positioning unit | V61K2284 |
Functional Description
Angle seat valveThe main parts of the angle seat valve are shown in the illustration below.The following instructions cover both NC (Normally Closed) and NO (Normally Open) valves.
- Actuator
- Valve stem
- Valve plug
- Valve house
No Product In Hepa (NPIH) systemIt is very important that product never reaches the HEPA filters in the machine for any reason. If this happens the hygiene in the machine will be lost. To prevent this from happening, a system consisting of an Air sensor, Pressure gauge, Product Relief Valve (PRV), High pipe and Non-return valve has been implemented on the machine.The first part of the system works by detecting air and high pressure in the product and consists of the Air sensor and the Pressure gauge. The second part is the relief part and works by closing the Product valve and opening the PRV when air or high pressure is detected. The system ensures that any product containing air or too high pressure is drained out without reaching the Product tank. During production, two scenarios can set a high product pressure yellow alarm. 1) The product pressure is higher than 200 kPa for more than 10 seconds.2) The pressure peaks at above 200 kPa for more than 2 seconds 10 times.If the alarm occurs the machine empties out all packages and steps down to program step Preheating.
- Air sensor
- Pressure gauge
- PRV
- High pipe
- Non-return valve
- Product valve
- Product tank
During CIP a yellow alarm occurs if the pressure is above 4 kPa for more than 2 seconds.If the Air sensor detects air during program step production, the PRV immediately opens and a blue alarm occurs. If air is detected for more than 10 seconds, the Product valve closes and the air in product yellow alarm occurs.Note: The pressure release function is disabled for ADY.During the program steps Tankfilling and Motor on the air in product yellow alarm is set immediately if the Air sensor detects air.Note: The pressure release function is disabled for ADY.The PRV can also be opened manually in certain program steps to purge unwanted product from the machine. See the OM for more information.As an added backup the HEPA air pipe into the Product tank also includes a Non-return valve. This Non-return valve stops any splash in the product tank so that it does not reach the HEPA air system. Splashing can be caused by bubbles that enter the Product tank. The non-return valve also stops product from reaching the HEPA air system through overfilling of the Product tank if the level probe fails for any reason.
- Air sensor
- Pressure gauge
- PRV
- High Pipe
- Non-return valve
- Product valve
- Product tank
Regulator Valve - Set Tank Level Valve
| Equipment Status | Program Step |
Note: For Machines with machine number 20082 or higher, see section .The valve is set and tested before delivery. These setting instructions are only to be used if further setting is required.- Remove the Cover.

- Cover
- Loosen the Holder and move to the side to avoid damage.
- Loosen and remove the Plate and the Clamp fitting.

- Holder
- Plate
- Clamp fitting
- Set the signal to 4mA, see Regulator Valve, Tank Level - Overhaul on page Regulator Valve, Tank Level - Overhaul.
- Make sure that the Valve plug is pressed against the valve seat.
- Set the valve Plug adjuster so that it is in contact with the actuator Piston rod.
- Tighten the Lock nut using a spanner.
- Fit and tighten the Clamp fitting and the Plate to connect the actuator Piston rod with the Valve plug.

- Plate
- Clamp fitting
- Valve plug
- Plug adjuster
- Piston rod
- Lock nut
- Check the stroke by changing the signal from 4 to 20mA, see Regulator Valve, Tank Level - Overhaul on page Regulator Valve, Tank Level - Overhaul. The stroke should be 20 ±1 mm.
- In case of deviation from the 20 mm stroke, see Procedure Regulator Valve - Set Tank Level Valve in Case of Deviation on page Regulator Valve - Set Tank Level Valve in Case of Deviation.
- Move the valve plug up and down several times and check that the valve plug is still in closed position. If not, start over from a).
- Set the holder, see Procedure Regulator Valve - Set Holder on page Regulator Valve - Set Holder.

A (mm) = 20
Regulator Valve - Set Tank Level Valve in Case of Deviation
| Equipment Status | Program Step |
Note: For Machines with machine number 20082 or higher, see section .The valve is set and tested before delivery. These setting instructions are only to be used if further setting is required!- Remove the Cover.

- Cover
- Loosen the Holder and move to the side to avoid damage.
- Remove the Plate and the Clamp fitting.
- Remove the Cover.

- Holder
- Plate
- Clamp fitting
- Cover
- Set the signal to 20 mA, see Regulator Valve, Tank Level - Overhaul on page Regulator Valve, Tank Level - Overhaul.
- Set with the zero-screw (clockwise) to ensure maximum open position.Note: Maximum stroke is 21 mm.
- Place a 20 mm Block between the actuator Piston rod and the valve Plug adjuster.
- Set the valve Plug adjuster to a distance A between the actuator Piston rod and the valve plug. Use a gauge blade to determine the 0.5 mm.

A (mm) = 20.5
B (mm) = 20
- Block
- Piston rod
- Plug adjuster
- Set with the zero-screw (counter-clockwise) until the actuator piston rod is in contact with the 20 mm block and the block can be moved slightly. Turn the zero-screw 1/2 turn (counter-clockwise) to set the valve plug under pressure.Note: Do not touch the zero-screw after the settings are done.
- Set the signal to 4 mA, see Regulator Valve, Tank Level - Overhaul on page Regulator Valve, Tank Level - Overhaul. The actuator piston rod is in contact with the valve Plug adjuster and sets the plug under pressure.
- Fit and tighten the Clamp fitting and the Plate to connect the actuator piston rod with the valve plug.

- Plate
- Clamp fitting
- Piston rod
- Plug adjuster
- Check the stroke by changing the signal from 4 to 20 mA, see Regulator Valve, Tank Level - Overhaul on page Regulator Valve, Tank Level - Overhaul. The stroke should be 20 ±1 mm.
- Set the holder, see Procedure Regulator Valve - Set Holder on page Regulator Valve - Set Holder.
Regulator Valve - Set Holder
| Equipment Status | Program Step |
Note: For Machines with machine number 20082 or higher, see section .- Adjust the Holder to set the distance B between the Proximity switch and the Plate. Make sure that the Proximity switch is in line with the Plate.
- Tighten the Nut.

B (mm) = 21 ±0.5
A (mm) = 5
- Holder
- Proximity switch
- Plate
- Nut
Product Relife Valve - Homing Control Unit
| Equipment Status | Program Step |
Every time that the control unit or product relief valve are serviced you must perform a homing of the control unit.A homing is always automatically performed when the machine is draining after a CIP.Incorrect homingMake sure that the pipes are empty and pressureless before homing the control unit.If the pipes are full or if they are pressurised, the home position will be incorrect.
Make sure that the product pipe is empty.- Connect a keyboard to the TPOP.
- Press the F4 key to open the
Service menu. - Press the Tank symbol.

- Tank symbol
- Press the Homing button for the side of the machine that you have worked on.
- Change the off choice to on with the Toggle button.
- Exit the window with the Exit button.
- Press Save to save the settings and to perform a homing of the control unit.

- Homing button
- Toggle button
- Exit button
- Save
Steam Trap - Clean
| Equipment Status | Steam must be turn OFF. Program Step |
Hot steam.Turn off the supply valve and release any pressure in the steam system before starting any work on the equipment.Pressurized steam can be discharged unexpectedly.
Burn hazard.Allow the pipes and components to cool down before starting any work on them. If this is not possible, use caution when working near the hot pipes and components.Pipes and components in the filling system can be hot.
- Unscrew the Cap and remove the Spacer plate, Cup, Spring and the Strainer screen.

- Housing
- Strainer screen
- Spring
- Cup
- Spacer plate
- Cap
- Check and clean the steam traps.
- Assemble in the reverse order. Make sure the stamped bulges on the spacer plate face upwards.Note: The steam traps have been positioned vertically. The steam enters at the top and is discharged at the bottom. Positioned like that, the traps are self draining.
Tank Valves and Pipes - Clean
| Equipment Status | Program Step |
Note: Use the detergents that are specified in the Chemicals for Cleaning and Disinfection table in the OM to clean the tank valves and pipes.- Remove the Valve A .
| Valve | Side 1 | Side 2 |
| A | V61M1270 | V61M2270 |
- Clean the Valve A.
- Remove the Valve B.
| Valve | Side 1 | Side 2 |
| B | V68M1256 | V68M2256 |
- Clean the Valve B.
- Loosen the Nut.

- Valve A
- Valve B
- Nut
- Disconnect the Air hose from the Valve C.
| Valve | Side 1 | Side 2 |
| C | V61M1275 | V61M2275 |
- Remove the Thermocouple D.
| Thermocouple | Side 1 | Side 2 |
| D | V61B1221 | V61B2221 |
- Disconnect the Pipe connection on the pipe that is connected to the steam trap E.
| Steam Trap | Side 1 | Side 2 |
| E | V61V1265 | V61V2265 |

Valid from machine number 63202/20111
- Air hose
- Valve C
- Thermocouple D
- Pipe connection
- Open the Clamp and remove the Sight glass and theValve C in one piece.
- Clean theSight glass and the Valve C.
- Open the Clamp and remove the Pipe.
- Clean the Pipe.
- Open the Clamp and remove the Pipe.
- Clean the Pipe.
- Make sure that no product has entered the HEPA-cabinet. If needed, clean the cabinet and change the filter, see Procedure HEPA Unit, FS - Change HEPA Filter.
- Assemble in the reverse order.

Valid from machine number 63202/20111
- Clamp
- Sight glass
- Clamp
- Pipe
- Clamp
- Pipe
Angle Seat-Valve - Change Stem Seals and Valve Kit
| Equipment Status | Steam must be turn OFF. Program Step |
| Consumables | Cleaning Detergent Alkali solution |
Hot steam.Pressurized steam can be discharged unexpectedly. Turn off the supply valve and release any pressure in the steam system before starting any work on the equipment.
Burn hazard.Pipes and components in the filling system can be hot. Allow the pipes and components to cool down before starting any work on them. If this is not possible, use caution when working near the hot pipes and components.
- Remove the Actuator top by turning by hand.

- Actuator top
- Remove the Nut and remove the Piston and Lower guide.
- Remove the Gland packing nut, and remove the Actuator and Valve stem.
- Remove the Nipple and remove the complete valve assembly.
- Pull out the old Packing set using a hook.
- Clean the packing box and all metal parts.

- Nut
- Piston
- Lower guide
- Gland packing nut
- Actuator
- Valve stem
- Nipple
- Packing set
- Change the actuator parts:
- If necessary change the valve kit: Pin and Valve plug.
- Assemble the angle seat valve in the reverse order.

- Packing set
- O-ring
- O-ring
- O-ring
- Packing
- O-ring
- Stem seal
- Packing
- Pin
- Valve plug
Steam Trap - Change
| Equipment Status | Steam must be turn OFF. Program Step |
Hot steam.Turn off the supply valve and release any pressure in the steam system before starting any work on the equipment.Pressurized steam can be discharged unexpectedly.
Burn hazard.Allow the pipes and components to cool down before starting any work on them. If this is not possible, use caution when working near the hot pipes and components.Pipes and components in the filling system can be hot.
- Unscrew the Cap and remove the Spacer plate, Cup, Spring, and the Strainer screen.

- Housing
- Strainer screen
- Spring
- Cup
- Spacer plate
- Cap
- Check and clean the steam traps.
- Change the strainer screen.
- Assemble in the reverse order. Make sure the three stamped bulges on the spacer plate face upwards.Note: The steam traps have been positioned vertically. The steam enters at the top and is discharged at the bottom. Positioned like that, the traps are self draining.
Diaphragm Valves - Change Diaphragm
| Equipment Status | Program Step ZERO |
| Special Equipment | Hook spanner 51-mm TP No. 90458-1547 Hook spanner 38-mm TP No. 90458-1546 Hook spanner 25-mm TP No. 90458-1545 Hook spanner 18-mm TP No. 90458-1544 Tightening tool TP No. 90600-0646 Pressure regulator, parts from the ejector TP No. 1304364-0101 |
Chemical hazard.Release any pressure and drain any fluids before starting any work on the filling system.The filling system could contain fluids and steam under pressure.
Burn hazard.Allow the pipes and components to cool down before starting any work on them. If this is not possible, use caution when working near the hot pipes and components.Pipes and components in the filling system can be hot.
- Remove the Pneumatic hose and the sensor Cable.Note: If more the one diaphragm valve is to be disassembled, give particular attention to the position of the hose and sensor cables connection on the actuator. This comes in handy during reassembling.

- Pneumatic hose
- Cable
Risk of equipment damage.Pressurise the actuator to the open position before loosening the locking ring.The threads of the locking ring can be damaged, if the locking ring is loosened when the actuator is in the closed position.
- Pressurise the Actuator with the pressure regulator to the open position.
- Loosen the Locking ring with a hook spanner. Remove the Actuator from the Valve body.
- Depressurise the Actuator to the closed position.
- Remove the Diaphragm.
- Change the Diaphragm.

- Actuator
- Locking ring
- Valve body
- Diaphragm
Risk of production fault.Always install the valve with the drain pointed downwards.If the drain of the valve is installed so that it is not pointed downwards fluids can collect in the valve and cause a hygienic risk.
Risk of equipment damage.Follow the instructions below and adjust the air pressure slowly.If the air pressure that is used to activate the actuator is too high, the diaphragm can become deformed and then damaged during the assembly.
- Pressurise the Actuator with the pressure regulator to the open position. Adjust the pressure slowly so that the Diaphragm lands on the Seat without deformation. See illustration A.If the pressure is too high, the diaphragm can become deformed and during the assembly, it can become damaged. See illustration B.

Illustration B

Illustration A
- Actuator
- Diaphragm
- Seat
Risk of equipment damage.The threads of the locking ring can be damaged if the locking ring is loosened when the actuator is in the closed position.
- Assemble the Actuator. Fit the diaphragm in the Valve body. Tighten the Locking ring with the hook spanner, the tightening tool, and torque wrench. See the table for torques.
| Valve size | Torque |
| 51 mm | 15 Nm |
| 38 mm | 15 Nm |
| 25 mm | 10 Nm |
| 18 mm | 7 Nm |
| 12 mm | 7 Nm |
- Pressurise or depressurise the Actuator five times.
- Tighten the Locking ring again. See the preceding table.

- Actuator
- Valve body
- Locking ring
Product Pressure Gauge - Change the Transmitter
| Equipment Status | Program Step |
Risk of burns.The pressure gauge is hot when it has been in use. Allow the pressure gauge to cool down before starting any work on it.
Risk of burns.The pipeline that the pressure gauge is connected to may be full of product, CIP solution or steam. Make sure that the pipeline is drained before starting any work on the pressure gauge.
Remove
- Disconnect the Connector from the Transmitter .
- Disconnect the Transmitter by opening the clamp at the Process connection.
Install
- Connect the pressure gauge at the Process connection.
- Connect the Connector to the Transmitter .

- Connector
- Transmitter
- Process connection
Product Air Sensor - Change
| Equipment Status | Program Step |
Risk of burns.The pressure gauge is hot when it has been in use. Allow the pressure gauge to cool down before starting any work on it.
Risk of burns.The pipeline that the pressure gauge is connected to may be full of product, CIP solution or steam. Make sure that the pipeline is drained before starting any work on the pressure gauge.
Remove
- Remove the Lid from the Air sensor by turning it counter clockwise.

- Lid
- Air sensor
- Disconnect the two Wire and the Ground wire.
Risk of damage to the equipment.The two
Sensor plates are easily damaged if they are bent or contaminated. Never handle or place the
Air sensor in such a way that the
Sensor plates are bent or damaged.
Open the Cable gland and pull out the Cable.- Disconnect the Air sensor by opening the Clamp at the Process connection.
- Air sensor
- Wire
- Ground wire
- Cable gland
- Cable
- Sensor plates
- Clamp
- Process connection
Install
- Install the Air sensor at the Process connection with the Clamp and theGasket. Make sure that the Sensor plates are parallel to the pipe according to the illustration below.
- Remove the Lid from the Air sensor by turning it counter clockwise.
- Insert the Cable through the Cable gland.
- Connect the two Wire and the Ground wire according to the illustration below.
- Tighten the Cable gland.
- Set the two Switches to Max and >0.7.
- Install the Lid.
- Lid
- Air sensor
- Wire
- Ground wire
- Cable gland
- Cable
- Sensor plates
- Clamp
- Process connection
- Gasket
- Switches
Regulator Valve, Tank Level - Overhaul
| Equipment Status | Program Step |
Note: For Machines with machine number 20082 or higher, see section .How to apply a current value
In order to apply a current of 4 mA or 20 mA do as follows:- Step the machine up to Air on.
- Turn the service key on.Note: The current supplied to the valve is now 20 mA.
- Turn the service key off.Note: The current supplied to the valve is now 4 mA.
Overhaul
Remaining fluids and steam.The filling system could contain fluids and steam under pressure. Release any pressure and drain any fluids before starting any work on the filling system.
Burn hazard.Pipes and components in the filling system can be hot. Allow the pipes and components to cool down before starting any work on them. If this is not possible, use caution when working near the hot pipes and components.
- Remover the cover, not shown on the picture.
- Step the machine up to AIR ON and turn the service key ON to open the valve.
- Remove the Clamp
- Step the machine down to step zero and turn the service key OFF to close the valve.
- Remove the valve and the L-ring.
- Loosen and remove the Holder

- Clamp
- L-ring
- Holder
- Loosen and remove the Plate and the Clamp fitting.
- Unscrew the Lock nut and valve Plug adjuster, using a spanner.

- Plate
- Clamp fitting
- Lock nut
- Plug adjuster
- Remove the assembled unit consisting of parts: L-ring, Guide ring, Diaphragm support, Diaphragm, Steam ring before dismantling.

- L-ring
- Guide ring
- Diaphragm support
- Diaphragm
- Steam ring
- Change the Guide ring , the Diaphragm support, Diaphragm, L-ring and the Steam ring.
- Assemble in reverse order.
- Set the holder, see Procedure Regulator Valve - Set Holder.
Regulator Valve Tank Level - Change
| Equipment Status | Program Step step zero |
Perform the following steps to exchange parts from old regulator valve to the new regulator valve.- Remove the Cover.

- Cover
- Loosen the Holder and move to the side to avoid damage.
- Loosen and remove the Plate .

- Holder
- Plate
- Assemble the Holder and the Plate on the new regulator valve in reverse order.
- Put the new Regulator valve in its place, and connect the air hose and the electrical supply cable.
Regulator Valve Tank Level - Overhaul
| Equipment Status | Program Step step zero |
Overhaul
Remaining fluids and steam.The filling system could contain fluids and steam under pressure. Release any pressure and drain any fluids before starting any work on the filling system.
Burn hazard.Pipes and components in the filling system can be hot. Allow the pipes and components to cool down before starting any work on them. If this is not possible, use caution when working near the hot pipes and components.
- Remove the cover, see section Regulator Valve Tank Level - Change, step Regulator Valve Tank Level - Change.
- Step the machine up to AIR ON.
- Check the position off the Actuator in relation to the Valve Body, make a mark of the position.Note: To ensure that the air hose, the cable, and the panel are in the correct position.
- Set the valve to 50% open according to manual mode on page Regulator Valve Tank Level - Settings.
- Loosen and remove the Upper Clamp.
- Unscrew the Clamp Fitting.
- Remove the Valve plug and separate the old diaphragm from the Valve plug. Discard the old diaphragm.
- Loosen and remove Lower Clamp.
- Remove Seat and O-ring from Valve Body.

- Actuator
- Valve Body
- Upper Clamp
- Clamp Fitting
- Valve plug
- Lower Clamp
- Seat
- O-ring
Changing the Diaphragm and the O-ring- Remove the old O-ring and replace with a new O-ring. Discard the old O-ring.
- Pre-mount the new Diaphragm without pressing it into the groove.
- Squeeze the Diaphragm into the groove using opposite pressure points.Note: Make sure that the Diaphragm is properly secured. See Pass/Fail below.

Pass

Fail
- Diaphragm
Reassemble- Install the Valve Body and the Upper Clamp.
- Install the Seat and the Lower Clamp.
- Set the valve to 0% open according to manual mode on page Regulator Valve Tank Level - Settings.
Regulator Valve Tank Level - Settings
| Equipment Status | Air must be turn ON.
|
Display Overview

- Operation locked
- Settings not yet saved in a non-volatile memory
- Unit
- Bar graph for system deviation
- Fault indication icon
- Manual mode
- Closed-loop operation icon
- Parameter/error code
- Fail-safe position active
Adapting the display
The display reading direction can be rotated by 180°. If the displayed data appear upside down, proceed as follows:- Touch the DOWN button or UP button until code P1 appears.
- Press the CONFIRM button for the selected code. P1 blinks.
- Touch the DOWN button or UP button until the Display is set in the desired direction.
- Press the CONFIRM button to set the Display direction.

- DOWN button
- CONFIRM button
- UP button
- Display
Enabling configuration to change parameters
Note: Before changing parameter settings in an initialized positioner, configuration must be enabled first by selecting Code P19:LOCK and the key icon indicate that the configuration is locked. Deactivate locking as follows:- Touch the DOWN button or UP button until code P19 appears.
- Press the CONFIRM button for the selected code. P19 blinks.
- Touch the DOWN button or UP button until OPEN is displayed.
- Press CONFIRM button to enable configuration.Note: If no settings are entered within three minutes, the enabled configuration function becomes invalid.
Adjusting the volume restriction
The volume restriction serves to adapt the air output capacity to the size of the actuator:- Set the Volume restriction to MIN.

- Volume restriction
Entering the direction of action
The signal pressure is the pneumatic pressure at the output of the positioner applied to the actuator.- Enable configuration according to Procedure Enabling configuration to change parameters.
- Touch DOWN button or UP button until Code P2 appears.
- Press CONFIRM button to set selected code. P2 blinks.
- Touch DOWN button or UP button until ATO (air to open) appears.
- Press CONFIRM button to confirm setting.Note: The changed direction of action first becomes effective after the positioner has been re-initialized.
The direction of action (P7) is set to increasing/increasing (>>) by default, i.e. when the positioner is initialized, 0% is displayed when the valve is closed and 100% when the valve is fully open. If necessary, the direction of action can be changed:- Enable configuration according to Procedure Enabling configuration to change parameters.
- Touch DOWN button or UP button until Code P7 appears.
- Press CONFIRM button to set selected code. P7 blinks.
- Ensure that P7 is set to default (increasing/increasing (>>)).
- The following correlation applies:
| Valve | CLOSED | OPEN |
| Reading | 0% | 100% |
| Direction of action increasing/increasing (>>) | 4 mA | 20 mA |
| Direction of action increasing/decreasing (<>) | 20 mA | 4 mA |
Limiting the signal pressure
If the maximum actuator force is too high for the valve used, the signal pressure limit can be activated in Code P9. The pressure is then limited to approx. 2.3 bar.- Enable configuration according to Procedure Enabling configuration to change parameters.
- Touch DOWN button or UP button until Code P9 appears.
- Press CONFIRM button to set selected code. P9 blinks.
- Touch DOWN button or UP button until OFF appears.
- Press CONFIRM button to confirm setting.
Setting other valid parameters
The following table lists the parameter codes and their default settings. Proceed in the same manner as previously described to change parameters.| Parameters codes |
| P0 | Status indication |
| P3 | Pin position [35] |
| P4 | Nominal range [MAX] |
| P5 | Characteristic [0] |
| P8 | Gain Kp [50] |
| P10 | End position w < [ON] |
| P11 | End position w > [OFF] |
| P14 | Display of reference variable w |
| P18 | RST Reset |
Initialization
During initialization the positioner adapts itself optimally to the friction conditions and the signal pressure required by the control valve.Risk of injury due to the actuator stem extending or retracting.Do not touch or block the actuator stem.
The process is disturbed by the movement of the actuator stem.Do not initialize the positioner while the process is running and only after isolating the plant by closing the shut-off valves.
The type and extent of self-adaptation depends on the preset parameters. MAX applies as the default setting for the nominal range (Code P4). During the initialization process, the positioner determines the total travel range or rotational range of the valve (from the CLOSED position to the opposite end position).Alternatively, a different travel can be selected in Code P4 (see code list in Setting other valid parameters.Note: The travel set in Code P4 is only limited during initialization. However, it might be exceeded in closed-loop control when the control signal is higher than 20 mA.Start initialization- Enable configuration according to Procedure Enabling configuration to change parameters.
- Touch DOWN button or UP button until Code P15 appears.
- Press CONFIRM button and hold for six seconds. 6...5...4...3...2...1 is counted down on the display.
The initialization starts and INIT blinks. The time required for the initialization procedure depends on the actuator transit time and can take a few minutes.
- Operation locked
- Closed-loop operation icon
- Initialization successfully completed. The positioner is in closed-loop operation indicated by the Closed-loop operation icon.
- The indicated value corresponds to the control position in %.
- Configuration is locked indicated by the Operation locked.
The Fault indication icon appears when the initialization fails. See section Fault.
- Fault indication icon
Manual mode
The valve position can be moved as follows using the Manual mode function:- Enable configuration according to Procedure Enabling configuration to change parameters.
- Touch DOWN button or UP button until Code P17 appears.
- Press CONFIRM button and hold for six seconds. 6...5...4...3...2...1 is counted down on the display and P17 blinks.
The manual set point is indicated on the display of an initialized positioner.The lever position in degrees in relation to the longitudinal axis is indicated on the display of a positioner that has not been initialized.
- Manual mode
- Touch DOWN button or UP button to change the manual set point.
Initialized positionerThe manual mode starts using the last set point used in closed-loop operation, ensuring a bumpless changeover.The bar elements on the display indicate the system deviation between the manual set point and set point used for closed-loop control while manually moving the valve in Code P17.The manual set point is adjusted in steps of 0.1%. You can move the valve controlled within its range.Positioner that has not been initializedTouch DOWN button or UP button for a long time to move the valve manually.The valve is only moved in one direction uncontrolled. The bar elements on the display indicate the change in direction.Touch CONFIRM button to deactivate manual mode.Note: The Manual mode function can only be exited as described or by interrupting the electrical supply (cold start). The positioner does not automatically exit this function and return to the display showing the status indication.
Fault
In case of a fault, the Fault indication icon is displayed. Switch past Code P0 or P20 to display the respective error code E0 to E15 together with ERR appear on the display. Refer to the Error codes list on page Error codes for the cause of the errors and the recommended action.Example:If, for instance, a travel has been entered in Code P4 (nominal range) which is larger than the maximum valve travel possible, the initialization process would be interrupted (E2 error code) because the rated travel would not have been reached (E6 error code). The valve moves to the Fail-safe position active.
- Fault indication icon
- Fail-safe position active


E2 error code: Initialization canceledE6 error code: Rated travel not achieved
The nominal range (Code P4) must be changed and the positioner re-initialized to remedy this problem.Parameter codes
| Code | Display, values [default setting] | Description |
| Note: Codes marked by an asterisk (*) indicate that the positioner needs to be re-initialized afterwards. |
| P0 | Status reading with basic information | The reading indicates the valve position or angle of rotation in % when the positioner is initialized. On touching the CONFIRM button when the positioner is not initialized, the position of the lever in relation to the mid-axis is displayed. |
| P1 | Reading direction | The reading direction of the display is turned by 180°. |
| P2* | ATO/ATC[ATO] | Parameter to adapt the positioner to how the control valve functions: ATO: Air to open (valve CLOSED in fail-safe position) ATC: Air to close (valve OPEN in fail-safe position). |
| P3 | Pin position17/25/[35]/50/90° | Insert follower pin in the proper position depending on the valve travel/opening angle. |
| P4 | Nominal range [MAX]Values with default setting [35]: e.g. 7.5/8.92/10.6/12.6/ 15.0/17.8/21.2 mm | Firmware 1.03 and lower:The possible adjustment range can be selected in stages depending on the selected pin position:17 From 3.75 to 10.6 mm25 From 5.3 to 15.0 mm35 From 7.5 to 21.2 mm50 From 10.6 to 30.0 mmFor 90°: Maximum range only, if P3 = 90°MAX: Maximum possible travel |
| Nominal range [MAX] | Firmware 1.10 and higher:The possible adjustment range can be selected in steps of 0.5 mm depending on the selected pin position:17 From 3.5 to 11.0 mm, alternatively MAX (up to 18.0 mm)25 From 5.0 to 16.0 mm, alternatively MAX(up to 25.0 mm)35 From 7.0 to 22.0 mm, alternatively MAX (up to 35.0 mm)50 From 10.0 to 32.0 mm, alternatively MAX (up to 50.0 mm)For 90°: Maximum range only, if P3 = 90°MAX: Maximum possible travel |
| P5 | Characteristic0 to 8[0] | Select characteristic:0, 1, 2 for globe valves, 0 to 8 with rotary actuators (P3 = 90°)0Linear1Equal percentage2Reverse equal percentage3SAMSON butterfly valve, linear4Linear5Linear6Linear7Linear8Linear |
| P6 | Reference variable[4 to 20 mA]SRLO/SRHI | For split-range operation:SRLO: low range 4 to 11.9 mASRHI: high range 12.1 to 20 mA |
| P7 | w/x[>>]/<> | Direction of action of the reference variable w to the travel/rotational angle x (increasing/increasing or increasing/decreasing) |
| P8 | Gain KP30/[50] | On initializing the positioner, the gain is set to the selected value. If the positioner hunts, the Kp value can be reduced. |
| P9 | Pressure limitationON/[OFF] | The signal pressure can take on the same pressure as the supply air at the maximum [OFF] or, in the case that the maximum actuator force can damage the valve, the pressure is limited to approx. 2.3 bar. |
| P10 | End position w <[ON]/OFF | Lower tight-closing function: If w reaches up to 1 % towards the final value that causes the valve to close, the actuator is immediately completely vented (with ATO - air to open) or filled with air (with ATC - air to close). |
| P11 | End position w >ON/[OFF] | Upper tight-closing function: If w reaches up to 99 % towards the final value that causes the valve to open, the actuator is immediately completely filled with air (with ATO - air to open) or vented (with ATC - air to close). |
| P14 | Info w InitializedNot initialized | Indicates the internally adjusted set point in the positioner (adjusted set point in 0 to 100 % according to the settings in P6 and P7). Touch the CONFIRM button to display external set point (applied set point in 0 to 100 % according to the 4-20 mA signal). |
| P15 | Start initialization | Press the CONFIRM button to cancel the initialization process. As a result, the valve moves to the fail-safe position. After a power supply failure during initialization, the positioner starts with the values of the last initialization (if available). |
| P16 | Start zero calibration | The zero calibration process can be interrupted by touching the CONFIRM button. The control valve returns to closed-loop operation.Note: A zero calibration cannot be started when E1 error code exists.After a power supply failure during zero calibration, the positioner starts with the settings from the last zero calibration. |
| P17 | Manual mode | Press the Down button or Up button to enter the set point. |
| P18 | Reset | Parameters are reset to their default setting.The positioner can only return to closed-loop operation after it has been re-initialized. |
| P19 | Enable configuration[LOCK]/OPEN | Enable configuration to change parameter settings. This function is automatically canceled when none of the keys are touched within three minutes. |
| P20 | Firmware version | Installed firmware version is displayed. Touch the CONFIRM button to display the last four digits of the serial number. |
Error codes
In case of a fault, the fault indication icon
is displayed.The errors listed in the following table are assigned to error classes:Error class 1: No operation possible.Error class 2: Manual operation only possible.Error class 3: Manual operation and closed-loop control possible.| Code | Description | Class |
| E0 | Zero error(operational error) | Only with tight-closing function P10 (end position w < set to ON). The zero point has shifted by more than 5% compared to initialization. The error may arise when the valve seat trim is worn. | 3 |
| Recommended action | Check valve and positioner attachment. If the positioner is mounted correctly, perform a zero calibration over Code P16 (see section 8.9). Error code can be reset (see section 8.12.1). | |
| E1 | Displayed and INIT values are not identical(operational error) | Adjusted and displayed valves are not identical to the INIT values as the parameters were changed after initialization. | 3 |
| Recommended action | Reset parameters or perform initialization. | |
| E2 | Positioner has not been initialized | Malfunction or parameter change requiring the positioner to be re-initialized. | 2 |
| Recommended action | Set parameters and initialize the positioner over Code P15. | |
| E3 | Kp setting(initialization error) | Positioner hunts.Volume restriction set incorrectly, too much gain. | 2 |
| Recommended action | Check the volume restriction setting as described in Adjusting the volume restriction. Limit gain KP in Code P8. Re-initialize the positioner. | |
| E4 | Transit time too short(initialization error) | The transit times of the actuator determined during initialization are so short (below 0.5 second) that optimal positioner tuning is not possible. | 2 |
| Recommended action | Check the volume restriction setting as described in section Adjusting the volume restriction. Re-initialize the positioner. | |
| E5 | Standstill detection is not possible | Supply pressure varies. Mounting incorrect. | 2 |
| Recommended action | Check supply air and positioner mounting. Re-initialize the positioner. | |
| E6 | Travel is not achieved during initialization | Supply pressure is too low, actuator leaks, incorrect travel adjusted or pressure limit function activated. | 2 |
| Recommended action | Check supply air, positioner mounting and setting. Re-initialize the positioner. | |
| E7 | Actuator does not move(initialization error) | No supply air, mounting blocked. | 2 |
| Recommended action | Check supply air, positioner mounting and mA input signal. Re-initialize the positioner. | |
| E8 | Travel signal at lower/ upper limit | Wrong pin position, wrong lever, wrong attachment direction when NAMUR attachment is used. | 1 |
| Recommended action | Reset error code (see section 8.12.1). Check positioner mounting and re-initialize the positioner. | |
| E9 to E15 | Device error (internal) | Return positioner to SAMSON AG for repair. | 1/3 |
Functional Description
The Fill pump is driven by a Servo motor. The Universal Product Valves Inlet UPV and UPV, and the Resuction device are pneumatically activated, and the timing is coordinated from the servo to ensure correct speed and accurate filling.The servo motor drives the fill pump. The servo motor contains a motor combined with a roller screw. This results in a reliable high-speed filling system. Each time that the machine steps up to program step Air on, a homing procedure is performed on the servo motors. The servo motor is oil cooled and lubricated in order to keep correct working temperature.Before production, air is purged from the system and a column of product stands ready for filling. This is activated on the TPOP. Both the Inlet UPV and the UPV are closed at the start of production.
- Fill pump
- Servo motor
- UPVInlet
- UPVOutlet
- Resuction device
Fill stroke:- Resuction is deactivated just after the start of filling.
- As the UPV opens, the piston moves forward to push product out of the Pump chamber.
- The outlet UPV closes at the end of the fill stroke, and the resuction device is activated just before the fill stroke ends.
Charge stroke:- The Inlet UPV opens and the piston moves backward to charge the Pump chamber.
- At the end of the charge stroke, the inlet UPV closes.
The process repeats itself throughout production.The Leakage detector detects any leakage behind the diaphragm in the Fill pump. The Leakage detector detects leakages in the Resuction device. The detectors are connected to different alarms on the TPOP.
- Fill pump
- Inlet UPV
- UPV
- Resuction device
- Pump chamber
- Leakage detector
- Leakage detector
Functional Description
TT/3_SCMThe Fill pump is driven by a Servo motor. The Universal Product Valve (UPV) is pneumatically activated, and the timing is coordinated from the servo to ensure correct speed and accurate filling.The servo motor drives the fill pump. The servo motor contains a motor combined with a roller screw. This results in a reliable high-speed filling system. The servo motor is oil cooled and lubricated to keep a correct working temperature.Before production, air is purged from the system and a column of product stands ready for filling. This is activated on the TPOP. The UPV is closed at the start of production.
- Fill pump
- Servo motor
- UPV
Fill stroke:Charge stroke:The process repeats itself throughout production.The Leakage detector detects any leakage behind the diaphragm in the Fill pump. The detectors are connected to different alarms on the TPOP.Risk of crushing and cutting hands and fingersTo prevent the valves from leaking, the filling valve servo motors are active in all program steps except STEP ZERO, even when the doors are open. Never put fingers or other materials between the piston (9) and the filling pipe (8).

- Fill pump
- UPV
- Tank
- Pump chamber
- Filling valve
- Leakage detector
- Filling pipe
- Piston
Piston Pump
Overview
Top: Side 2Bottom: Side 1
| Side 1 | Side 2 |
| Pos | Description | Function no | Pos | Description | Function no |
| 1 | Servomotor S1:1 | V60M3221 | 3 | Servomotor S2:1 | V60M4221 |
| 2 | Servomotor S1:2 | V60M5221 | 4 | Servomotor S2:2 | V60M6221 |
Universal Product Valve, Diaphragm Valve, and Resuction Device
Overview
Side 1Side 2
| Side 1 | Side 2 |
| Pos | Description | Function no | Pos | Description | Function no |
| 1 | Tank product drain valve | V60M1279 | 4 | Tank product drain valve | V60M2279 |
| 2 | UPV Upper S1:1 | V60M3263 | 5 | UPV Upper S2:1 | V60M6263 |
| 3 | UPV Upper S1:2 | V60M4263 | 6 | UPV Upper S2:2 | V60M5263 |
The positions 7 to 12 are not valid for the ADY and ASCM variant.| Side 1 | Side 2 |
| Pos | Description | Function no | Pos | Description | Function no |
| 7 | UPV Lower S1:1 | V60M3265 | 10 | UPV Lower S2:1 | V60M6265 |
| 8 | UPV Lower S1:2 | V60M4265 | 11 | UPV Lower S2:2 | V60M5265 |
| 9 | Re-suction device | | 12 | Re-suction device | |
Piston Pumps - Check Piston Centring
| Equipment Status | Program Step |
| Special Equipment | Adjustment pin TP No. 2929048-0000 |
Remaining fluids and steam.The filling system could contain fluids and steam under pressure. Release any pressure and drain any fluids before starting any work on the filling system.
Burn hazard.Pipes and components in the filling system can be hot. Allow the pipes and components to cool down before starting any work on them. If this is not possible, use caution when working near the hot pipes and components.
Preparations of the Piston Pump
- Disassemble the piston pump, follow the sub procedure
Risk of damage to the equipment.The piston surface can easily be damaged, which can lead to premature failure of the diaphragms. Never use a vice to hold the piston unit.
Remove the six Screw, the Connection plate and the Rear diaphragm from the Piston.- Remove the Nut, the Washer, the Plate, and Front diaphragm.
- Reassemble a Piston unit with a Connection plate, six Screw and a Piston.Note: The procedure is valid for variant Base, Midi, and Mini. The procedure for variant Micro is similar to that procedure and therefore not described.

- Screw
- Connection plate
- Rear diaphragm
- Piston
- Nut
- Washer
- Plate
- Front diaphragm
- Piston unit
- Install the Piston unit using the Clamp. Align the guide pin (by the arrow).
- Reassemble the pump cylinder
- Remove the Plug.
- Turn the roller screw using a screwdriver, until the Piston unit is lined up with the end of the Pump cylinder.

- Piston unit
- Clamp
- Pump cylinder
- Guide pin
- Clamp
- Plug
Check Piston Centring in Pump Cylinder
- Check the Piston position in the Pump cylinder. Use the Adjustment pin to detect if there is any deviation in the piston centring. The adjustment pin must without any difficulty be able to run in the gap A, around the piston in the pump cylinder. If the gap A is not according to the table below the feeler pin will get jammed and the piston needs to be repositioned.Note: The large end of the adjustment pin is to be used for variant Base, Midi, and Mini. The small end of the adjustment pin is to be used for variant Micro.
- If there is a deviation in the centring of the Piston adjust the alignment of the Servomotor and Motor cradle by turning the screws, see Procedure Piston Pump - Set Piston Centring.

Base, Midi, Mini A (mm) ≥ 6
Micro A (mm) ≥ 3.5
- Piston
- Pump cylinder
- Adjustment pin
- Servomotor
- Motor cradle
- To reassemble the piston pump first remove the Piston unit and then disassemble the piston unit:
- Turn the roller screw using a screwdriver, until the Piston unit is in its rear end position.
- Tighten the Plug.
- Remove the Clamp and the Pump cylinder. Make sure that you do not lose the Guide pin.
- Remove the Clamp and remove the Piston unit. Make sure that you do not lose the guide pin (by the arrow).

- Piston unit
- Clamp
- Pump cylinder
- Guide pin
- Clamp
- Plug
Risk of damage to the equipment.The piston surface can easily be damaged, which can lead to premature failure of the diaphragms. Never use a vice to hold the piston unit.
Remove the Screw and the Connection plate.- Assemble the piston unit, follow the sub procedure

The illustration shows variant Base, Midi, and Mini
- Screw
- Connection plate
- Follow the sub procedure
Piston Pump - Set Piston Centring
| Equipment Status | Program Step |
| Special Equipment | Adjustment pin TP No. 2929048-0000 |
The Screw in the Distance between the Servomotor and Motor cradle , can be used for adjusting the servomotors contact surface against the motor cradle. Turning the screw will adjust the axle position of the servomotor and effect the Piston centring. If the piston is leaning towards one side of the pump cylinder the screw on the opposite side needs to be adjusted to compensate for the incorrect position of the axle.
- Screw
- Distance
- Servomotor
- Motor cradle
- Piston
Centre Piston - Work Sequence:
- Make sure that the Screw is loosened, and that they are not in contact with the Motor cradle.
- Check the position of the Piston in the Pump cylinder with the Adjustment pin, to find out which way the piston is leaning.Note: The large end of the adjustment pin is to be used for variant Base, Midi, and Mini. The small end of the adjustment pin is to be used for variant Micro.
- Measure the gap at the point where the adjustment pin got jammed.
- Loosen the four Screw.
- Make adjustments by turning the Screw.Note: See the tables and illustrations below for guidance.
- Slightly tighten the Screw not used for adjustments, they must just be in contact with the Motor cradle.
- Tighten the Screw. Tighten the Screw.
- Check if the Piston is centred in the Pump cylinder. Repeat the procedure until the Adjustment pin can run through the gap without getting jammed.

- Screw
- Motor cradle
- Piston
- Pump cylinder
- Adjustment pin
- Screw
Adjustment Guidance
| Leaning direction | Guidance illustration (see next page) |
| 135º | Illustration A |
| 180º | Illustration B |
| 270º | Illustration C |
| Left, right, upwards, and downwards adjustments |
| Number of turns | Adjustment by the piston (mm) |
| 0.25 | 0.5 |
| 0.5 | 1 |
| 0.75 | 1.5 |
| 1 | 2 |
| Diagonal adjustments |
| Number of turns | Adjustment by the piston (mm) |
| 0.25 | 0.7 |
| 0.5 | 1.4 |
| 0.75 | 2.1 |
| 1 | 2.8 |
Illustration Leaning Direction and Adjustments

Top: Illustration AMiddle: Illustration BBottom: Illustration C
Piston Pump - Lubricate the Guide Shaft
| Equipment Status | Program Step Step Zero |
| Special Equipment | Grease gun: TP No. 950926-0000 |
| Consumables | Grease: TP No. 344407-0000 |
- Lubricate the servomotor Axle (and bushing). Use a Grease gun, insert it in the Lubrication nipple in the Middle piece.Note: Remove surplus lubrication.

- Axle
- Grease gun
- Lubrication nipple
- Middle piece
Piston Pump - Change Diaphragms
| Equipment Status | Program Step |
| Special Equipment | Ejector TP No. 1304364-0101 |
Remaining fluids and steam.The filling system could contain fluids and steam under pressure. Release any pressure and drain any fluids before starting any work on the filling system.
Burn hazard.Pipes and components in the filling system can be hot. Allow the pipes and components to cool down before starting any work on them. If this is not possible, use caution when working near the hot pipes and components.
Piston Pump - Disassembly
- Check that the gauge at the vacuum pump reads -0.7 to -0.8 bar.
- Loosen the Pump chamber by removing the Clamp.
- Loosen the Screw and slide the piston pump in the direction of the arrow. Make sure that you do not lose the Guide pin.
- Loosen the Screw until you can lift and turn the Bracket as shown in the illustration below.
- Remove the Cover.

- Pump chamber
- Clamp
- Screw
- Guide pin
- Screw
- Bracket
- Cover
- Disconnect the Vacuum hose from the connection. Plug the vacuum hose.
- Remove the Clamp and the Pump cylinder.
- Make sure that you do not lose the Guide pin.
- Remove the Clamp and remove the Piston unit. Make sure that you do not lose the guide pin (by the arrow).
- Place the Piston unit on a clean suitable working area.

- Vacuum hose
- Clamp
- Pump cylinder
- Guide pin
- Clamp
- Piston unit
Piston Unit - Change Diaphragms
Risk of Damaging Equipment.The piston surface can easily be damaged, which can lead to premature failure of the diaphragms. Never use a vice to hold the piston unit.
- Remove the six Screw, the Connection plate and the Rear diaphragm from the Piston.
- Remove the Nut, the Washer, the Front plate, and the Front diaphragm.

Left: DisassemblyRight: Reassemble
- Screw
- Connection plate
- Rear diaphragm
- Piston
- Nut
- Washer
- Front plate
- Front diaphragm
- Use a soft cloth and cleaning solution according to the OM to clean the Piston.
- Assemble the new Front diaphragm and the Front plate on the Piston.
- Make sure that the diaphragm is correctly placed in the recess of the piston. Firmly hold the Front plate and fold the Front diaphragm over the Piston. Check for folds, smooth out if necessary.
- Turn the Piston and place the Washer in the indentation in the centre of the piston. Install the Front plate and assemble by tightening the Nut.
- Assemble the new Rear diaphragm, the rear Connection plate, and the six Screw on the Piston.
- Make sure that the diaphragm is correctly placed in the recess of the piston. Check for folds, smooth out if necessary.

DisassemblyReassemble
- Screw
- Connection plate
- Rear diaphragm
- Piston
- Nut
- Washer
- Front plate
- Front diaphragm
Piston Pump - Reassemble
- Use a soft cloth and cleaning solution according to the OM to clean the Pump cylinder.
- Attach the Piston unit to the Servomotor, using the Clamp. Align the guide pin (by the arrow).
- Slide the Pump cylinder over the Piston unit. Align the Guide pin.
- Assemble the Clamp.

- Pump cylinder
- Piston unit
- Servomotor
- Clamp
- Guide pin
- Clamp
- Connect the hose from the Vacuum tool to the Elbow connection at the Pump cylinder.
- Connect compressed air to the pressure regulator (by the arrow).
- Adjust the air pressure until the gauge reads 2.5 to 3.0 bar, (correspond to an under pressure of -0.6 to -0.8 bar).
- Press the outer sealing surface of the Front diaphragm in to the groove of the Pump cylinder with your fingers. Hold for a moment. Check for folds and wrinkles, smooth out if necessary.
- If the diaphragm still has wrinkles, remove the Plug and move the piston backwards and forwards by turning the roller screw using a screwdriver. When the diaphragm is in place and it has no wrinkles move the piston to the end position and put the plug back.
- Turn off and remove the Vacuum tool.

- Pump cylinder
- Vacuum tool
- Elbow connection
- Front diaphragm
- Plug
- Use a soft cloth and cleaning solution according to the OM to clean the Pump chamber .
- Slide the piston pump in the direction of the arrow.
- Assemble the Pump chamber to the Pump cylinder, align the two Guide pin and attach using the Clamp.
- Tighten the Screw.
- Assemble the Cover, fasten the Bracket with the Screw.
- Connect the vacuum hoses in the Elbow connection.
- Check that the gauge on the vacuum pump reads -0.7 to -0.8 bar.

- Pump cylinder
- Elbow connection
- Pump chamber
- Guide pin
- Clamp
- Screw
- Cover
- Bracket
- Screw
Piston Pump - Change Diaphragms and Seals
| Equipment Status | Program Step |
| Special Equipment | Vacuum generator TP No. 1304364-0101 |
Remaining fluids and steam.The filling system could contain fluids and steam under pressure. Release any pressure and drain any fluids before starting any work on the filling system.
Burn hazard.Pipes and components in the filling system can be hot. Allow the pipes and components to cool down before starting any work on them. If this is not possible, use caution when working near the hot pipes and components.
Piston Pump - Disassembly
- Check that the gauge on the vacuum pump reads -0.7 to -0.8 bar.
- Disconnect the Vacuum hose from the Connection. Plug the vacuum hose.
- Loosen the Pump head by removing the Clamp. Make sure that you do not lose the Guide pin.
- Loosen the Screw and slide the piston pump in the direction of the arrow.
- Remove the Clamp.
- Remove the Pump cylinder. Make sure that you do not lose the Guide pin.
- Loosen the Screw until you can lift and turn the Bracket as shown in the illustration below.
- Remove the Cover.
- Remove the Clamp and remove the Piston unit. Make sure that you do not lose the guide pin (by the arrow).
- Place the piston unit on a clean suitable working area.

- Vacuum hose
- Connection
- Pump head
- Clamp
- Guide pin
- Screw
- Clamp
- Pump cylinder
- Guide pin
- Screw
- Bracket
- Cover
- Clamp
- Piston unit
Piston Unit - Change Diaphragms
Risk of damage to the equipment.The piston surface can easily be damaged, which can lead to premature failure of the diaphragms. Never use a vice for holding the piston unit.
- Remove the Nut, the O-ring, the Cap and Front diaphragm from the Piston.
- Remove the Screw, the Connection plate, the O-ring and the rear Diaphragm.
- Use a soft cloth and cleaning solution according to the OM to clean the Piston.
- Place the new rear Diaphragm , the new O-ring, and the Connection plate on the Piston. Make sure that the diaphragm is correctly placed in the recess of the piston.
- Fold the new rear Diaphragm over the Piston. Check for folds, smooth out if necessary.
- Tighten the Screw.
- Assemble the new Front diaphragm, the new O-ring, the Cap, and the Nut. Make sure that the diaphragm is correctly placed in the recess of the piston
- Fold the new Front diaphragm over the Piston. Check for folds, smooth out if necessary.

- Nut
- O-ring
- Cap
- Front diaphragm
- Piston
- Screw
- Connection plate
- O-ring
- Diaphragm
Piston Pump - Reassemble
- Use a soft cloth and cleaning solution according to the OM to clean the Pump cylinder.
- Attach the Piston unit to the Servomotor, using the Clamp. Align the guide pin (by the arrow).
- Apply a very thin layer of silicon grease to the Bead of each diaphragm.Note: Make sure that the layer of grease is very thin, to avoid getting the grease sucked into the vacuum system. Make sure that the grease is not applied on the product side.
- Make sure that the diaphragm bead fits correctly in the groove on the Adaptor.
- Slide the Pump cylinder over the Piston unit. Align the Guide pin.
- Assemble the Clamp.

- Pump cylinder
- Piston unit
- Servomotor
- Clamp
- Bead
- Adaptor
- Guide pin
- Clamp
- Connect the hose from Vacuum tool to the Elbow connection at the Pump cylinder.
- Connect compressed air to the pressure regulator (by the arrow).
- Adjust the air pressure until the gauge reads 2.5 to 3.0 bar, (correspond to an under pressure of -0.6 to -0.8 bar).
- Press the outer sealing surface of the Front diaphragm in to the groove of the Pump cylinder with your fingers. Hold for a moment. Check for folds and wrinkles, smooth out if necessary.
- Turn off and remove the Vacuum tool.

- Pump cylinder
- Vacuum tool
- Elbow connection
- Front diaphragm
- Use a soft cloth and cleaning solution according to the OM to clean the Pump head.
- Slide the piston pump in the direction of the arrow.
- Assemble the Pump head to the Pump cylinder, align the two Guide pin and attach using the Clamp.
- Tighten the Screw.
- Turn off and remove the Vacuum tool. Connect the vacuum hose in the Elbow connection.
- Assemble the Cover, fasten the Bracket with the Screw.
- Check that the gauge on the vacuum pump reads -0.7 to -0.8 bar.

- Pump cylinder
- Vacuum tool
- Elbow connection
- Pump head
- Screw
- Guide pin
- Clamp
- Screw
- Cover
- Bracket
- Screw
Piston Pump - Change Diaphragms due to Breakdown
| Equipment Status | Program Step production |
| Special Equipment | Vacuum generator TP No. 1304364-0101 Diaphragm insert tool TP No. 1094870 (Micro) |
Remaining fluids and steam.The filling system could contain fluids and steam under pressure. Release any pressure and drain any fluids before starting any work on the filling system.
Burn hazard.Pipes and components in the filling system can be hot. Allow the pipes and components to cool down before starting any work on them. If this is not possible, use caution when working near the hot pipes and components.
Note: The installation of new diaphragms require the filling system to be cleaned and sterilised before production can start again. This can be done with the other side in production, if the process equipment is connected to the machine with separate product lines. Perform CIP and SIP before starting production on the serviced side.- If one side is still in production, step that side down to tank filling.
Risk of damage to the equipment.The vacuum system creates vacuum for the piston pumps on both Side 1 and Side 2 in all program steps. If the vacuum system is interrupted in production or end production, the piston pump diaphragms can be damaged. Make sure that the machine is in tank filling (or in a lower program step) on both Side 1 and Side 2, before removing the vacuum hoses from the piston pumps.
Disconnect the vacuum Hose from the pump to be serviced, at the Leakage detector. Use a Hose-hose connection and a Blanking plug to plug the Hose.- Check that the gauge on the vacuum pump reads -0.7 to -0.8 bar.
- If it is desirable to run production on the side where the service work is not performed, step that machine side up to production.

- Hose
- Leakage detector
- Hose-hose connection
- Blanking plug
- Change the diaphragms following the procedure
- Step the side where the service work is not performed down to tank filling.
- Remove the Leakage detector glass and wipe the inside of the glass and the detector house. Check the condition of the gaskets. Change, if necessary.
- Clean the vacuum system according to Vacuum System - Clean.
- Restore all the vacuum hoses. Remove the Blanking plug and the Hose-hose connection and connect the Hose onto the leakage detector.
- Check that the gauge on the vacuum pump reads -0.7 to -0.8 bar.
- Step the side where the service work is not performed up to production.
- Perform CIP and SIP on the side being serviced.

- Hose
- Hose-hose connection
- Blanking plug
- Leakage detector glass
- Vacuum hose
Piston Pump - Change Servomotor Oil
| Equipment Status | Program Step Step Zero |
| Special Equipment | Tray |
| Consumables | Hydraulic Oil: TP No. 1607000-0000 |
Burn hazard.The oil in the oil container can be hot. Allow the oil to cool down before draining the system.
- Remove the Hose from the Nipple on the Oil container. Place the hose in a tray and drain the system.
- Remove the oil container Lid.
- Make sure that the Filter, integrated in the Lid, is clean. If necessary, clean the filter using compressed air.
- When the system is drained, fill the Oil container with new oil to the marking A (see illustration) approximately 30 mm below the lid.

- Hose
- Nipple
- Oil container
- Lid
- Filter
Rubber Spacer and Washers - Change
| Equipment Status | Program Step |
| Special Equipment | Vacuum generator TP No. 1304364-0101 |
Burn hazard.The servomotor and adjacent parts can be hot. Allow the servomotor to cool down before starting any work on it.
- Disconnect the Vacuum hose. Plug the vacuum hose.
- Connect the Vacuum tool to the pump cylinder. Connect compressed air to the vacuum tool (by the arrow).
- Adjust the air pressure to the gauge reads 2.5 to 3 bar, (correspond to an under pressure of -0.6 to -0.8 bar).Note: The vacuum tool must be connected during the whole procedure.

- Vacuum hose
- Vacuum tool
- Loosen the Screw until you can lift and turn the Bracket as shown in the illustration below.
- Remove the Cover.
- Remove the Clamp.
- Remove the Plug and turn the roller screw until the servomotor shaft is in its rear end position.
- Push the piston unit in the direction of the arrow.
- Remove the Screw and washer from the steering.

- Screw
- Bracket
- Cover
- Clamp
- Plug
- Screw and washer
- Remove the Hub.
- Remove the two Bolt.
- Remove the old Rubber spacer and replace it with a new one.
- Install the Hub.
- Turn the roller screw clockwise until the recession of the Servomotor shaft is aligned with the Rubber spacer . Make sure that the key handle on the servomotor shaft fits over the pin on the Hub.
- Tighten the Screw and washer, until the steering is in contact with the servomotor shaft.

- Plug
- Screw and washer
- Hub
- Bolt
- Rubber spacer
- Servomotor shaft
- Pull the piston backwards and assemble the Clamp.
- Screw in thePlug.
- Assemble the Cover with the Bracket with the Screw.
- Remove the two Screw and the Washer.
- Use a thin tool, for example a small screwdriver, to remove the two Rubber washer .
- Install new rubber washers with the Washer and the Screw.
- Disconnect the Vacuum tool and connect the Vacuum hose.
- Check the piston centring according to Piston Pumps - Check Piston Centring.

- Screw
- Washer
- Rubber washer
Universal Product Valve - Check
| Equipment Status | Program Step |
Remaining fluids and steam.The filling system could contain fluids and steam under pressure. Release any pressure and drain any fluids before starting any work on the filling system.
Burn hazard.Pipes and components in the filling system can be hot. Allow the pipes and components to cool down before starting any work on them. If this is not possible, use caution when working near the hot pipes and components.
Check before Removal
- Make sure that:

- Spring
- Rod end
- Ball
- Bushing
- Air cylinder
- Bushing
- Swivel flange
- Spacer
- Throttle check valve
Check after Removal
- Remove the valve, see part of procedure Universal Product Valve - Overhaul.
- Make sure that:
- Check the overtravel with the Spring attached
- overtravel should be 0.3 mm to 0.7 mm.
- Check the valve rubber components for damage.

- Valve
- Gasket
- Spring
Final Steps
- Install valve (parts of procedure Universal Product Valve - Overhaul).
- Check valve setting (procedure Universal Product Valve - Set).
Re-Suction Device - Check Diaphragms
| Equipment Status | Program Step |
Remaining fluids and steam.The filling system could contain fluids and steam under pressure. Release any pressure and drain any fluids before starting any work on the filling system.
Burn hazard.Pipes and components in the filling system can be hot. Allow the pipes and components to cool down before starting any work on them. If this is not possible, use caution when working near the hot pipes and components.
- Remove the Ejector.
- Remove the Clamp and the Re-suction device including the Re-suction diaphragm.
- Check the condition of the Re-suction diaphragm and if necessary change it according to the procedure Re-Suction Device - Change Diaphragms.
- Re-assemble in the reverse order.

- Ejector
- Clamp
- Re-suction device
- Re-suction diaphragm
Flexible Pipe - Check Diaphragms
| Equipment Status | Program Step |
Remaining fluids and steam.The filling system could contain fluids and steam under pressure. Release any pressure and drain any fluids before starting any work on the filling system.
Burn hazard.Pipes and components in the filling system can be hot. Allow the pipes and components to cool down before starting any work on them. If this is not possible, use caution when working near the hot pipes and components.
- Remove the Clamp and the Flexible pipe including the Diaphragm.
- Check the condition of the Diaphragm, if necessary change them according to the procedure Flexible Pipe - Change Diaphragms.

- Clamp
- Flexible pipe
- Diaphragm
Universal Product Valve - Set
| Equipment Status | Program Step |
Set Overtravel
Note: The setting is to be done with the spring unit installed.Make sure that the valve closes completely. A small overtravel is to be set.- Lift the Yoke to open the valve. Then let the valve close by itself.
- Measure the gap A and make a note of it.
- Push the Yoke downwards until the piston reach its end position.
- Measure the gap A again. It should be a difference of 0.3 to 0.7 mm between the two measurements. (=overtravel).
Basic Setting of Throttle Valves
- Close both the Throttle valve and Throttle valve completely by turning the screws.
- Open the Throttle valve by turning the screw:
- Turn 4 revolutions counter clockwise.
- Open the Throttle valve ) by turning the screw:
- Turn 7 revolution counter clockwise.

- Yoke
- Throttle valve
- Throttle valve
Set Spring
Make sure that the spring is attached as shown in the illustration.Note: Put a little grease on the springs end and open about 1 mm gap the springs first turn.- Insert the left end of the Spring into the first hole in the Small holder . Turn the spring until it fits into all holes.
- Insert the right end of the spring in the hole on the Spring holder and turn until all, but the last Hole on each row are filled. There should be one empty on each row and the end of the spring should be just in or about to enter the last hole in the lower row.
- Make sure that the Ball moves easily.

- Spring
- Small holder
- Spring holder
- Hole
- Ball
Universal Product Valve - Set Leaking Universal Product Valve
| Equipment Status | Program Step step zero |
Remaining fluids and steam.The filling system could contain fluids and steam under pressure. Release any pressure and drain any fluids before starting any work on the filling system.
Burn hazard.Pipes and components in the filling system can be hot. Allow the pipes and components to cool down before starting any work on them. If this is not possible, use caution when working near the hot pipes and components.
Leakage from the front edge (1)
- Add Shims between the Yoke and the Upper block. Use the instructions in Universal Product Valve - Overhaul to disassemble and assemble the universal product valve.
- Check that the valve does not leak according to Universal Product Valve - Overhaul on page Universal Product Valve - Overhaul.

- Front edge
- Shims
- Yoke
- Upper block
Leakage from the rear edge (5)
- Remove Shims between the Yoke and the Upper block. Use the instructions in Universal Product Valve - Overhaul to disassemble and assemble the universal product valve.
- Check that the valve does not leak according to Universal Product Valve - Overhaul.

- Shims
- Yoke
- Upper block
- Rear edge
Universal Product Valve - Set Leaking Universal Product Valve
| Equipment Status | Program Step |
Remaining fluids and steam.The filling system could contain fluids and steam under pressure. Release any pressure and drain any fluids before starting any work on the filling system.
Burn hazard.Pipes and components in the filling system can be hot. Allow the pipes and components to cool down before starting any work on them. If this is not possible, use caution when working near the hot pipes and components.
- Check that the Valve cone is centred in the Valve body.
- Place the fingertips in the middle between the four screws on the yoke.
- Press the Yoke downwards lightly (pressure equivalent to the force of 0.2 kg).

- Valve cone
- Valve body
- Yoke
- Check that the gap A (at the valve front) is 1 to 1.5 mm (and no gap at all at the back).
- If necessary, adjust the gap by adding or removing Shim between the Yoke and the Upper clamp.
- Check once again that the gap A is 1 to 1.5 mm.

- Yoke
- Shim
- Upper clamp
Re-Suction Device - Clean the Leak Detection System
| Equipment Status | Program Step step zero |
Remaining fluids and steam.The filling system could contain fluids and steam under pressure. Release any pressure and drain any fluids before starting any work on the filling system.
Burn hazard.Pipes and components in the filling system can be hot. Allow the pipes and components to cool down before starting any work on them. If this is not possible, use caution when working near the hot pipes and components.
- Remove the Housing and the leaking resuction diaphragm according to Re-Suction Device - Change Diaphragms.
- Clean the Housing.
- Install a new diaphragm and re-install the Housing.
- Prepare a clean container and fill it with one litre of clean water.
- Disconnect the Hose between the T-pipe and the Ejector.Note: Never disconnect theHose between the Ejector and the sensors.
- Disconnect the Ejector from the Housing.
- Connect a piece of Hose to the vacuum side of the T-pipe.

- Housing
- Hose
- T-pipe
- Ejector
- Hose
- Hose
- Put the Hose into the water and blow with compressed air through the hose you disconnected from the T-pipe until all the water has been sucked through the Ejector.
- Remove the Hose from the container and blow some more compressed air through the ejector to dry the system.
- Assemble the system in the reverse order.

- Housing
- Hose
- T-pipe
- Ejector
- Hose
- Hose
Re-Suction Device - Change Diaphragms
| Equipment Status | Program Step step zero |
Remaining fluids and steam.The filling system could contain fluids and steam under pressure. Release any pressure and drain any fluids before starting any work on the filling system.
Burn hazard.Pipes and components in the filling system can be hot. Allow the pipes and components to cool down before starting any work on them. If this is not possible, use caution when working near the hot pipes and components.
- Remove the Ejector.
- Remove the Clamp and the Re-suction device including the Re-suction diaphragm.
- Change the Re-suction diaphragm.
- Install the Re-suction device including the Re-suction diaphragm, using the Clamp.
- Install the Ejector.

- Ejector
- Clamp
- Re-suction device
- Re-suction diaphragm
Flexible Pipe - Change Diaphragms
| Equipment Status | Program Step |
Remaining fluids and steam.Release any pressure and drain any fluids before starting any work on the filling system.The filling system could contain fluids and steam under pressure.
Burn hazard.Allow the pipes and components to cool down before starting any work on them. If this is not possible, use caution when working near the hot pipes and components.Pipes and components in the filling system can be hot.
- Remove the Clamp and the Flexible pipe including the Diaphragm.
- Change the Diaphragm.
- Install the Flexible pipe including the Diaphragm, using the Clamp.

- Clamp
- Flexible pipe
- Diaphragm
Universal Product Valve - Overhaul
| Equipment Status | Program Step |
| Special Equipment | Tool TP No. 2697051 (Base, Midi, Mini) Tool TP No. 1339397 (Micro) Tube TP No. 2704204-0000 |
Remaining fluids and steam.Release any pressure and drain any fluids before starting any work on the filling system.The filling system could contain fluids and steam under pressure.
Burn hazard.Allow the pipes and components to cool down before starting any work on them. If this is not possible, use caution when working near the hot pipes and components.Pipes and components in the filling system can be hot.
- Disconnect the Connection point for air hose from non-return Throttle valve.Note: Make sure that the air hoses are connected at correct connection points, after removal.
- Remove Upper clamp and Lower clamp. If the Gasket are worn dispose them and install new ones, see sub-procedure Install Universal Product Valve page Install Universal Product Valve.
- Lift out the valve.

- Universal Product Valve
- Throttle valve
- Connection point for air hose
- Upper clamp
- Lower clamp
- Gasket
Remove Air Cylinder and Spring
- Remove
- Check the Spring. If it shows signs of fatigue or ware, change it to a new spring during assembly.
- Check the Link head. If they are worn, change to new ones during assembling. Make sure that the joint balls rotate easily.

- Bolt
- Link head
- Retainer
- Air cylinder
- Shaft
- Spacer
- Spring unit
- Spring
Remove Yoke and Bushings
- Remove the Screw, the Block and the Shim. Note: Write down the amount of Shim on top of and underneath the Block, this will come in handy during the assembly. Only Micro machines have Shim underneath the Block.
- Remove the Screw, the Thrust washer and the Yoke.Note: The two thrust washers will be assembled on the air cylinder side only. This will give access to Cylinder bracket.

- Screw
- Block
- Shim
- Screw
- Thrust washer
- Yoke
- Cylinder bracket
- Bushing
Remove the Cylinder Bracket and Valve Cone
- Remove the Screw and the Cylinder bracket.
- Carefully turn and work the Valve cone out from under the valve body. If the cone is worn or damaged, change to a new one.
- If the machine is a Micro machine, remove the O-ring (Only Micro). Only Micro machines have the O-ring (Only Micro).

- Screw
- Cylinder bracket
- Valve cone
- O-ring (Only Micro)
Install the Valve Cone
- Put soap around the Valve cone rubber part to ensure it is not completely dry.
- Carefully, avoiding damage to rubber, work Flange part from underneath to its place.
- Insert Tool to hold the valve cone in place.
- If the machine is a Micro machine, fit the O-ring (Only Micro) in the work Flange part. Only Micro machines have the O-ring (Only Micro).
- Install the valve body, the valve cone and Tool in Clamp . Do not tighten the clamp yet.
- Centre the valve rod and Flange sideways between the two Blocks on the valve body on the valve body. Tighten the Clamp until the flanges of the valve body and the tool are fully home.
- Put the Cylinder bracket in place. Install and secure the Screw.

- Cylinder bracket
- Screw
- Valve cone
- O-ring (Only Micro)
- Flange
- Tool
- Clamp
- Blocks on the valve body
Install the End Plate, Block, Yoke, Thrust Washers and Bushings
- Install the Bushing in the Yoke.
- Install the Yoke on the valve body.
- Put the two Thrust washer on the same side as the air cylinder is to be installed. One of the washers on each side of the yoke holder.Note: A small amount of grease holds the washers in place.
- Centre the Thrust washer hold with the two Screw. Tighten the bolts properly.
- Set the Block.

- Screw
- Block
- Shim
- Screw
- Thrust washer
- Yoke
- Cylinder bracket
- Bushing
- Place the Shim on the top of the Block. Note: Use the same amount and distribution of shims as before the disassembling. The basic distribution of shims are 6 shims at the top and 2 shims underneath the block.
- Let the block easily slide into place, secure the unit by the Screw.
- Remove the Clamp and the Tool.
- Check that the Valve cone is centred in the valve body and that it is possible for the valve cone to move smoothly (by its own weigh) between open and closed.

- Screw
- Block
- Shim
- Valve cone
- Tool
- Clamp
Install Spring and Air Cylinder
Make sure that the spring is attached as shown in the illustration.Note: Put a little grease on the springs end and open about 1 mm gap the springs first turn.- Insert the left end of the Spring into the first hole in the small Holder. Turn the spring until it fits into all holes.
- Insert the right end of the spring in the hole on the spring Holder and turn until all, but the last Hole on each row are filled. There should be one empty on each row and the end of the spring should be just in or about to enter the last hole in the lower row.

- Spring
- Holder
- Holder
- Hole
- Install the Spring unit.Note: Check that the Ball of the air cylinder and spring unit moves easily. Too much friction can cause malfunction. If the ball is binding, strike slightly with a hammer to loosen it.
- Install the Shaft and the Spacer.
- Install the Air cylinder and the Locking washer.
- Set the link head to fit the Screw with the air cylinder piston in its inner end position (to get the exact position). Then tighten the Screw properly.

- Spring unit
- Ball
- Shaft
- Spacer
- Air cylinder
- Locking washer
- Screw
Leakage Check Using Water
- Connect the Tube (TP No. 2704204-0000) to the universal product valve, according to the illustration below.Note: Use the big flange for Base, Midi and Mini. Use the small flange for Micro.
- Fill the tube with water up to a 1400 mm height.
- Check the valve for any visual leaks.
- Lift the Yoke slightly and release some water.
- Check for leaks again.
- If any leaks are found, set the universal product valve according to Universal Product Valve - Set Leaking Universal Product Valve if the machine is a Base, Midi or Mini and according to Universal Product Valve - Set Leaking Universal Product Valve if the machine is a micro.

Left: Base, Midi, MiniRight: Micro
- Yoke
Install Universal Product Valve
Note: Check re-suction diaphragm (see procedure , page , before installing the outlet valves.- Set the Universal Product Valve in place.Note: If the Gasket where worn and disposed of, put in new gaskets.
- Attach the Lower clamp and the Gasket.
- Attach the Upper clamp and the Gasket.
- Connect the Connection point for air hose to the Throttle valve.
- Set the Universal Product valve (see Procedure Universal Product Valve - Set, on page Universal Product Valve - Set).

- Universal Product Valve
- Throttle valve
- Connection point for air hose
- Upper clamp
- Lower clamp
- Gasket
Piston Pump - Check Oil Level and Quality
| Equipment Status | Program Step Step Zero |
| Special Equipment | Tray |
| Consumables | Hydraulic Oil: TP No. 1607000-0000 |
- Check the oil level in the Oil container. If the oil level is below the marking A (see illustration), approximately 30 mm below the lid, refill the oil. See Procedure Piston Pump - Change Servomotor Oil on page Piston Pump - Change Servomotor Oil.

- Oil container
Check Oil Quality- To find out if there is water in the oil use one (or both) of these methods:
- Perform a “crackle test”: Pour a sample of the oil in a large spoon. Heat the spoon from the underside (by a cigarette lighter). If there is water in the oil it will start boiling and crackles.
- Take an oil sample in a glass and let it “rest” for a while. If there is water in the bottom, the oil needs to be changed.
Piston Pump - Change Servomotor
| Equipment Status | Power must be turn OFF.
|
- Disconnect the cables from the Connection. Make sure that they face downwards before assembling the new motor.

- Connection
- Loosen the Screw until you can lift and turn the Bracket as shown in the illustration.
- Remove the Cover.
- Release and remove the Clamp.
- Open the Inlet UPV manually, and at the same time, push the Piston to the maximum front position. Remove the Screw.

- Screw
- Bracket
- Cover
- Clamp
- Inlet UPV
- Piston
- Screw
- Remove the four Nut, and secure that the Rear part stays in position.Note: Make sure that the Rear part and the Front part are not divided from the Servo motor during the disassembly.
- Remove the Servo motor by sliding it backward and put it on a work bench.

- Nut
- Front part
- Rear part
- Servo motor
Burn hazard.The oil in the
Oil container can be hot. Allow the oil to cool down before draining the system.
- Remove the Hose from the Nipple on the Oil container. Place the Hose in a tray and drain the system.
- Remove the Oil container from the Servo motor together with all connections. The Oil container and the connections are reused when assembling the new servo motor.
- Assemble the four threaded rods and the nuts on the broken Servo motor to make sure that no oil is leaked.
- Move the plastic plugs for the connections from the new servo motor to the old servo motor.
- Change the Servo motor and assemble in the reversed order.Note: Fill the Oil container with new oil before assembling the new servo motor.Note: Make sure that the Key grip in the front of the shaft is in correct position when assembling the motor. If the Key grip is not in the correct position, it is not possible to tighten the screw that was removed in Item .

- Servo motor
- Hose
- Nipple
- Oil container
- Key grip
Universal Product Valve - Check
| Equipment Status | Power must be turn ON. Air must be turn ON. Steam must be turn ON. Water must be turn ON.
|
Burn hazard.Allow the filling system to cool down before working on or near it.The surfaces on the filling system are hot and can cause serious burns.
Check with Valves on Machine
- Make sure that:
- The Spring is not fatigued. (When the Spring is in rest position there should be no space between the coils.)
- There is no play in the Rod end and the Ball moves freely.
- The radial play is < 0.3 mm in the Bushing.
- The Air cylinder does not have external leakage or internal leakage between the two internal chambers. If any doubt, change the air cylinder.
- The radial play is < 0.3 mm in the Bushing and in the Swivel flange.
- The Spacer is not worn or missing.
- The Throttle check valve does not leak air, and are tightened against the Air cylinder.

- Spring
- Rod end
- Ball
- Bushing
- Air cylinder
- Bushing
- Swivel flange
- Spacer
- Throttle check valve
Check after Valves are Removed from Machine
- Remove the UPV from the machine. See Procedure Universal Product Valve - Overhaul. Make sure that:
- Check rubber components of the valve for ruptures.
- Check the overtravel. See Procedure Universal Product Valve - Set.
- Install the valve. See Procedure Universal Product Valve - Overhaul.
- Check the setting of the valve. See Procedure Universal Product Valve - Set.

- Valve body
- Gasket
Universal Product Valve - Overhaul
| Equipment Status | Power must be turn ON. Air must be turn OFF. Steam must be turn ON. Water must be turn ON.
|
| Special Equipment | Tool for 3 in. valve (TP No. 1309007) Tool for 2 in. valve (TP No. 1339397) Setting tool (TP No. 2789096) |
Remaining fluids and steam.Drain any fluids before starting any work on the filling system.The filling system could contain fluids.
Burn hazard.Allow the pipes and components to cool down before starting any work on them. If this is not possible, use caution when working near the hot pipes and components.Pipes and components in the filling system can be hot.
- Disconnect the connection points for Connection points for air hose from the Throttle check valve.Note: Make sure that the correct air hose is replaced later. If the hose does not have a number, label it before removing it.

- Connection points for air hose
- Throttle check valve
- Remove the Inlet UPV.
- Check the gaskets in the clamps. If they are worn, change the gaskets. See Procedure Pipe Gaskets - Change.

- UPVInlet
Remove Air Cylinder and Spring
- Remove the Spring unit by stretching the Spring and slide the spring holder off the Shaft.
- Remove the Spacer.
- Remove the Shaft with the Retaining ring shaft.
- Remove the Air cylinder and the Spring unit by removing the Bolt.
- Check the Spring. If the spring is fatigued, change the spring during reassembly.(When the Spring is in rest position there should be no space between the coils.)
- Check the Rod end. If they are worn, change the rod ends during reassembly. Make sure that the joint balls rotate easily.

- Bolt
- Rod end
- Retaining ring shaft
- Air cylinder
- Shaft
- Spacer
- Spring unit
- Spring
Remove Yoke and Bushings
- Loosen the Screw (total of four), the Block and Shim, and the End plate.Note: Note the number of Shim located above and below the block. This will be helpful during reassembly.
- Remove the Screw (total of two) and remove the Thrust washer (total of two).
- Remove the Yoke.
- Check the Bushing (total of two). If they are worn, change the bushings during reassembly.Note: The two thrust washers will be assembled on the air cylinder side only.
- This will give you access to the Holder.

- Screw (total of four)
- Block
- Shim
- End plate
- Screw (total of two)
- Thrust washer (total of two)
- Yoke
- Bushing (total of two)
- Holder
Remove the Holder and Valve Cone
- Remove the four Screws (total of four), the Holder, and the O-ring.
- Carefully turn the Valve cone and work it out of the valve body.
- If the valve cone is worn or damaged, change the valve cone.

- Screws (total of four)
- Holder
- O-ring
- Valve cone
Install the Valve Cone
- Apply soap around the rubber part of the Valve cone. This is to lubricate the rubber for easier insertion.
- Carefully work the Flange part of the Valve cone in through the side of the valve housing and into place.
- Make sure that the Valve cone is centred and that the Flange is in place in the Opening.
- Wash off all visible soap.

- Flange
- Valve cone
- Opening
Install the Cylinder Bracket
Risk of damage to the equipment.Do not force the flange to move its position. If the parts are not aligned, loosen the screws and realign vertically.
- Insert the Setting tool (TP No. 2789096) to hold the valve cone in its proper place. Clamp the setting tool in place until the UPV is assembled.
- Put the O-ring and Holder in place and secure it using the Screws (total of four).
- Align the bracket to the flange (not shown).

- Setting tool (TP No. 2789096)
- O-ring
- Holder
- Screws (total of four)
Install End Plate, Block, Yoke, Screws, Thrust Washers, and Bushings
- Install the Yoke and the Bushing (total of two).
- Install the two Thrust washer (total of two) on the air cylinder side. Insert these washers so that one is on each side of the yoke holder.Note: The Thrust washer (total of two) MUST be on the air cylinder side.
- Install the Screw (total of two).
- Set the End plate and the Block.
- Place the same number of Shim on the top and the bottom of the block.
- When the block slides easily into place, secure the unit using the four Screw (total of four).
Install and Set Spring and Air Cylinder
- If a new Spring is needed, attach it as shown below.

- Small spring holder
- Holes in small spring holder
- Spring
- Spring holder
- Holes in spring holder
- Ball
- Install the Bolt. Tighten the bolts properly.
- Install the Air cylinder.
- The balls in the Rod end must move easily. If it does not, strike it lightly with a plastic hammer to loosen it.
- Install the Shaft with the Retaining ring shaft and Spacer.
- Install the Spring unit.
- The balls in the Rod end must move easily. Too much friction can cause a malfunction. If the ball does not move easily, strike it lightly with a plastic hammer to loosen it.Note: The Spring unit and the air cylinder assembly may be reversed depending on the direction of the pump.

- Bolt
- Rod end
- Retaining ring shaft
- Air cylinder
- Shaft
- Spacer
- Spring unit
- Spring
- Check for leakage using water.
- Connect a 1 m Pipe to the Universal Product Valve using a 3 in. Clamp.Note: The illustration of the Universal Product Valve is only schematic.
- Fill the Pipe with 80 cm of water.
- Check visually for leakage.
- Lift the yoke slightly and release. Water will be released. When the valve closes again, there should be no more leakage.
- Adjust if leakage occurs. Add or remove a shim under the yoke and test again until there is no leakage.

- Pipe
- Clamp
- Universal Product Valve
Install Universal Product Valve
Note: Check the resuction diaphragm before installing the outlet valves.- Set the UPV in place.
- Attach the Lower clamp and gasket.
- Attach the Upper clamp and gasket.
- Connect the Connection points for air hose to the non-return Throttle check valve.
- Set the Universal Product Valve. See Procedure 6.4.2.5-3 Universal Product Valve - Set.

- Connection points for air hose
- Throttle check valve
- Upper clamp and gasket
- Lower clamp and gasket
Servo Motor - Change
| Equipment Status | Power must be turn OFF.
|
Mechanical Risk of damage to the equipment.Be careful when connecting the cables to the motor. Ensure that the cable connectors are properly connected and tightened.The cable connector pins break easily.
- Disconnect the Cable.
Note: If changing more than one motor, make sure to connect the cables at the same position during the assembly. This is due to individual IP-addresses.- Remove the Clamp.

- Cable
- Clamp
- Gently pull the Servo motor up and push it to the side to disengage the Servo motor from the Shaft.

- Servo motor
- Shaft
- Remove the Housing by removing the Screw and the Washer.

- Housing
- Screw
- Washer
- Check the condition of the Knob.
- Change if necessary or move the Knob to the new servo motor.

- Knob
- Assemble in the reverse order.Note: Make sure that the threading in the cable connectors are correctly connected. Tighten the cables.
Servo Motor - Set
| Equipment Status | Power must be turn ON.
|
| Special Equipment | Expert software for Tritex version 4.5.2.6 or higher (Expert4_5_2_6.zip) Motor Service Cable, TP No. 90603-8653 Software configuration file for Exlar Servo motors: - ExlarConfig_Motor11.zip - ExlarConfig_Motor12.zip - ExlarConfig_Motor21.zip - ExlarConfig_Motor22.zip |
- Set the machine in program step step zero.
- Install Expert Software for Tritex.
- Unzip Expert4_5_2_6.zip.
- Run Setup.exe.
- Follow the on-screen instructions.
- Unzip corresponding TritexEthernetConfig file to a location on your PC.
Risk of damage to the equipment.Be careful when connecting the cable to the motor. The cable connector pins break easily.
Remove the protection plug and connect the M8 Motor Service Cable to the servo motor, and to an available USB slot on your PC.Note: It is important to connect the programming cable to the correct motor and then download the corresponding configuration file for that specific servo motor. If done incorrect, the commands from the filling machine are sent to the wrong servo motor.
- Check that power is supplied to the servo motor.
- Start Expert software for Tritex.
- Select File - Open - Application
- In the dialogue box, click
Browse Other Appl.
- Select the configuration file.Note: It is important that the correct configuration file is selected for the servo motor you are working with.
Configure Network- Select View - Network Communications Manager.
- Select
Add Network.
- Select
Modbus RTU.
- Select the Communication port that the Communication cable is connected to. Other settings, as shown in picture.
- Select Drive - Write Parameters to drive
- Parameters are downloaded to the drive.
- When the parameters are downloaded, go to Networks - Ethernet/IP.
- In the Edit TCP/IP properties, click
Save Addresses to Drive.
- When the parameters are set, close the application and cycle power to the servo drive.Note: Network settings will not be affective until power is cycled.
- Disconnect the M8 Motor Service Cable from the servo motor and put the protection plug back in place.
Functional Description
The Tank are provided with a level probe and its floating body is provided with a permanent magnet. The product level is measured by the floating body through magnetic transfer.
- Tank
Tank Bracket - Check Leakage Detector
| Equipment Status | Program Step |
- Press the Catch and pull the Leakage detector out.
- Touch the Housing with the Pin. Make sure that the Pin touches metal.
- Make sure that the yellow alarm for leakage in the vacuum system is set.
- If no alarm is set the Leakage detector is not working and must be replaced and checked again.
- Reinstall the Leakage detector again.
- Reset the alarm.

- Catch
- Leakage detector
- Housing
- Pin
Tank Bracket - Check Level Probe
| Equipment Status | Program Step |
Remaining fluids and steam.Release any pressure and drain any fluids before starting any work on the filling system.The filling system could contain fluids and steam under pressure.
Burn hazard.Allow the pipes and components to cool down before starting any work on them. If this is not possible, use caution when working near the hot pipes and components.Pipes and components in the filling system can be hot.
- Check the function by measuring the resistance between the wires.
- Black and brown.The resistance decrease proportionally according to the position of the floating body.
- Blue and brown.The resistance increase proportionally according to the position of the floating body.
- Black and blue.Shows the total resistance independent of position of the floating body.
| Wires | Position of the floating body |
| 0% | 50% | 100% |
| Black and brown | 1 Ohm | 4.5 Kilo-ohm | 9 Kilo-ohm |
| Blue and brown | 9 Kilo-ohm | 4.5 Kilo-ohm | 1 Ohm |
| Black and blue | 9 Kilo-ohm | 9 Kilo-ohm | 9 Kilo-ohm |
- Check for short-circuit. Measure the resistance between each wire and the housing of the level probe.

- Nut
- Sealing washer
- Lid
- Gasket
- Level probe
- Floating body
- Clamp
- Gasket
- Tank
Tank Bracket - Change Tank Non Return Valve
| Equipment Status | Program Step STEP ZERO |
| Consumables | Gasket, TP No. 342850-0206 |
Remaining media.The filling system could contain media under pressure. Before service, make sure that the valves and the pipes are drained and pressureless.
Hot parts in the filling system.Use caution when working inside the filling system.Pipes and components in the filling system can cause burn damages.
- Remove the Clamp and the Gasket.
- Move the Pipe to the side.
- Remove the Non return valve.
- Install the new Non return valve.
- Move the Pipe into position.
- Change to a new Gasket and fit the Clamp.

- Clamp
- Gasket
- Pipe
- Non return valve
Tank Bracket - Change Tank Gasket
| Equipment Status | Program Step |
| Consumables | Gasket, TP No. 90005-0153 |
Remaining media.The filling system could contain media under pressure. Before service, make sure that the valves and the pipes are drained and pressureless.
Hot parts in the filling system.Use caution when working inside the filling system.Pipes and components in the filling system can cause burn damages.
- If there is an agitator in the tank, remove the drive unit on the outside. See Procedure Tank Bracket - Change Motor.
- Remove the Clamp.
- Move the Pipe to the side and remove the Gasket.
- Remove the Non return valve.

- Clamp
- Pipe
- Gasket
- Non return valve
- Remove the Tank clamp.
- Remove the Tank lid from the tank.
- Change the Tank gasket.
- Install the Tank lid with the Tank clamp and tighten the Tank clamp.
- Install the Non return valve.
- Move the Pipe into position.
- Install new Gasket and the Clamp and tighten the Clamp.

- Tank clamp
- Tank lid
- Tank gasket
Tank Bracket - Drain Detector
| Equipment Status | Program Step |
Risk of damage to the equipment.Make sure that the machine is in tank filling (or in a lower program step) on both Side 1 and Side 2, before removing the vacuum hoses from the piston pumps.The vacuum system creates vacuum for the piston pumps on to both Side 1 and Side 2 in some program steps. If the vacuum system is interrupted the piston pump diaphragms can be damaged.
- Remove the glass and drain the condensation water.
- Wipe the detector and the glass dry and assemble the glass.
- Step the machine up to Production.

- Glass
Tank Bracket - Change Motor
Agitator TT/3 | Equipment Status | Power must be turn OFF.
|
- Mark the cables regarding connection.
- Disconnect the motor cables in the electrical cabinet.
- Loosen the Tank lid.
- Remove the Motor and the Tank lid from the tank.
- Assemble in the reverse order with a new motor.Note: Check that the indicator lights on the new motor are visible.

- Clamp
- Motor
Tank Bracket - Check Bearings
Agitator TT/3 | Equipment Status | Power must be turn OFF.
|
| Special Equipment | Lifting tool, TP No. 90606-8294 |
| Consumables | Grease: TP No. 344407-0000 |
- Remove the Clamp and the Motor.Note: Failure to do this can cause the ceramic bearing to brake.
- Remove the Tank lid. See Procedure Tank Bracket - Change Tank Gasket.

- Tank lid
- Clamp
- Motor
- Lower the Lifting tool into the tank. Hook on to the agitator Mixer head.
- Lift up and remove the agitator Mixer head with the female bearing.Note: The Mixer head is fragile. Be careful not to touch the opening when lifting the Mixer head out off the tank.

- Lifting tool
- Mixer head
- Turn the Lifting tool around and remove the Male bearing.

- Lifting tool
- Male bearing
- Check that no splinters have come off from the Male bearing and the Female bearing.To change the bearings, see Procedure Tank Bracket - Change Bearings.
- Apply grease on the threads of the Male bearing.Note: Grease should only be applied on the threads. Whip of surplus grease on other parts of the Male bearing.
- Assemble in the reverse order with the new O-ring.Note: Before the mixer head is assembled, check that the O-ring is in position.
- Tighten the Male bearing with a torque of 6Nm.
- Check that the indicator lights on the motor are visible when mounted back.

- Male bearing
- O-ring
- Female bearing
Tank Bracket - Change Bearings
Agitator TT/3 | Equipment Status | Power must be turn OFF.
|
| Special Equipment | Lifting tool, TP No. 90606-8294 Female Bearing Replacement Kit, TP No. 90606-8299 |
| Consumables | Grease: TP No. 344407-0000 |
- Remove the Male bearing and the mixer head with the Female bearing. See Procedure Tank Bracket - Check Bearings.
- Find the Female Bearing Replacement Kit.
- Change the Female bearing by warming it up with the heater in the Replacement Kit.
- Apply grease on the threads of the Male bearing.Note: Grease should only be applied on the threads. Whip of surplus grease on other parts of the Male bearing.
- Assemble in the reverse order with the new O-ring.Note: Before the mixer head is assembled, check that the O-ring is in position.
- Tighten the Male bearing with a torque of 6Nm.

- Male bearing
- O-ring
- Female bearing
Vacuum System Functional Description
The purpose of the vacuum system is to make sure that the diaphragms are always in contact with the piston pumps. This ensures that the diaphragms do not fold or break prematurely. Compressed air enters the system through the Connection and is regulated with the Valve. The vacuum is continuously measured by the Pressure guard and the Valve opens when the vacuum is above -60 kPa (-0.6 bar) and it remains open for 10 seconds to build up the vacuum again. If the vacuum is above the allowed value for more than 30 seconds the blue alarm occurs. If the vacuum rises above -50 kPa (-0.5 bar) the yellow alarm occurs. The vacuum itself is generated in the Ejector as the compressed air passes through it and out the Hose. The passing air sucks out the air in the rest of the system and creates the vacuum. The vacuum is preserved with the Non-return valve.
- Connection
- Valve
- Pressure guard
- Ejector
- Hose
- Non-return valve
There is one vacuum cabinet for each side of the machine. The system is then divided at the T-connection and supplies both piston pumps for that side of the machine. The Non-return valve and Non-return valve ensures that if one diaphragm leaks, the other piston pump will not be contaminated.The vacuum system is always supplied with compressed air, even if the machine is stepped down to program step Zero.
- T-connection
- Non-return valve
- Non-return valve
Alarms and Troubleshooting Filling Section
110305181/110305182
DescriptionCompressed air enters the system through the Connection and is regulated with the Valve. The vacuum is continuously measured by the Pressure guard and the Valve opens when the vacuum is above -60 kPa (-0.6 bar) and it remains open for 10 seconds to build up the vacuum again. Conditions to set the alarmIf the vacuum is above the allowed value for more than 30 seconds the blue alarm (S1) 110305181 or (S2) 110305182 occurs.
- Connection
- Valve
- Pressure guard
Troubleshooting- Check all the hoses and connections in the system for leaks. Repair any leaks that you find.
- Check if the sight glasses of the drain detectors are loose. Tighten any loose sight glasses.
- Make sure that the Valve is functioning by starting it manually. Press the button on the Valve to start it. Check the value on the Pressure guard when the Valve is open. The value will change if the valve is functioning.
110305191/110305192
DescriptionCompressed air enters the system through the Connection and is regulated with the Valve. The vacuum is continuously measured by the Pressure guard and the Valve opens when the vacuum is above -60 kPa (-0.6 bar) and it remains open for 10 seconds to build up the vacuum again.Conditions to set the alarmIf the vacuum rises above -50 kPa (-0.5 bar) the yellow alarm (S1) 110305191 or (S2) 110305192 occurs.
- Connection
- Valve
- Pressure guard
Troubleshooting- Check all the hoses and connections in the system for leaks. Repair any leaks that you find.
- Check if the sight glasses of the drain detectors are loose. Tighten any loose sight glasses.
- Make sure that the Valve is functioning by starting it manually. Press the button on the Valve to start it. Check the value on the Pressure guard when the Valve is open. The value will change if the valve is functioning.
Vacuum System - Clean
| Equipment Status | Program Step air on |
| Special Equipment | Clean 1 litre water container |
| Consumables | Clean water, 1 litre |
- Change the leaking diaphragm and empty and clean the leaking piston pump according to Piston Pump - Change Diaphragms or Piston Pump - Change Diaphragms and Seals.
- Remove the cover from the Vacuum box.
- Prepare a clean container and fill it with 1 litre of clean water.
- Disconnect the Hose from the cleaned piston pump and put the disconnected end in the clean water.
- Open the Valve with the Switch and run the vacuum system until all the clean water has been sucked up. This flushes out most of the contamination from the vacuum system.
- Connect the Hose to the piston pump to make that side airtight and to make item Reference below possible.
- Fill the container with clean water again.
- Disconnect the Hose from the Drain detector on the uncontaminated side and put the disconnected end in the clean water.

- Vacuum box
- Hose
- Valve
- Switch
- Hose
- Drain detector
- Open the Valve with the Switch and run the vacuum system until all the clean water has been sucked up. This flushes out the last contamination from the vacuum system.
- Disconnect the Hose from the cleaned piston pump to prepare the system for drying.
- Open the Valve with the switch and run the vacuum system for one minute and suck air to dry the system.
- Connect the Hose to the piston pump
- Connect the Hose to the Drain detector.
- Install the cover.
Steam Unit
Hot steam.Use protective gloves when handling the regulator valve or turning off the supply valve. Use caution when working near the hot equipment.Pipes and components can be very hot.
Hot steam.Turn off the supply valve and release any pressure in the steam system before starting any work on the machine or equipment.Pressurized steam can be discharged unexpectedly.
Read the section Steam Supplyin the Safety Precautions chapter.
- Supply valve
- Steam filter
- Strainer
- Regulator
- Pressure gauge
Steam Unit - Set Pressure
| Equipment Status | Program Step |
Hot steam.Use protective gloves when handling the regulator valve or turning off the supply valve. Use caution when working near the hot equipment.Pipes and components can be extremely hot.
- Perform a basic setting by adjusting the steam pressure. Turn the Regulator and check that the pressure gauge (2) after the filter reads approximately 120 kPa to 140 kPa (1.2 to 1.4 bar).
- Choose sip on the TPOP according to OM, and run SIP on both Side1 and Side 2.
- Adjust the steam pressure with the Regulator during the sterilisation and check that the Pressure gauge, after the filter, reads approximately 110 kPa to 120 kPa (1.1 bar to 1.2 bar).
- Check that the steam temperatures shown on the TPOP is above 122° C, see OM. Check the steam temperatures on both sides.
- If necessary, adjust the steam pressure so that the steam temperatures shown on the TPOP is above 122° C.

- Regulator
- Pressure gauge
Steam Unit - Clean Strainer
| Equipment Status | Steam must be turn OFF. Program Step AIR ON |
Hot steam.Use protective gloves when handling the regulator valve or turning off the supply valve. Use caution when working near the hot equipment.Pipes and components can be extremely hot.
Hot steam.Turn off the supply valve and release any pressure in the steam system before starting any work on the machine or equipment.Pressurized steam can be discharged unexpectedly.
- Turn off the main steam supply by turning the Ball valve to closed position. Check that the Pressure gauge, Pressure gauge, and Pressure gauge reads 0kPa (0bar).
- Remove the Protective cover.

- Ball valve
- Pressure gauge
- Pressure gauge
- Pressure gauge
- Protective cover
- End cap
- Strainer
- Open the End cap on the Strainer and take out the mesh. Clean the mesh by using compressed air.
- Assemble the Strainer and the Protective cover.
- Turn on the steam supply by slowly turning the Ball valve to the opened position. Check that the Pressure gauge reads more than 350 kPa. If it does not, set the steam pressure. See Procedure Steam Unit - Set Pressure on page Steam Unit - Set Pressure.

- Ball valve
- Pressure gauge
- Pressure gauge
- Pressure gauge
- Protective cover
- End cap
- Strainer
Steam Unit - Clean Filter Cartridge
Hazardous procedure and quality assurance.It is strongly recommended to return the filter insert to the supplier for cleaning.Can cause personal injury and/or be a hygiene risk.
Contact your local supplier for handling of filter inserts.Collect a number of filter cartridge, TP No. 90459-3195, to send to the supplier for cleaning.If the cleaning procedure can not be performed by the supplier, the filter should be disposed of.Steam Pressure Gauge - Change the Transmitter
| Equipment Status | Power must be turn OFF.
|
Hot steam.Make sure that you release any pressure in the steam system before starting any work on the pressure gauge.The pipeline that the pressure gauge is connected to may be full of very hot steam under high pressure.
Risk of burns.Let the pressure gauge cool down before starting any work on it.The pressure gauge is hot when it has been in use.
- Disconnect the Connector from the Transmitter.
- Remove the old Transmitter from the Connection.
- Change the Gasket.
- Assemble the new Transmitter.
- Connect the Connector at the Transmitter.

- Connector
- Transmitter
- Connection
- Gasket
Functional Description
Valid for FestoThe main pneumatic unit supplies units in the filling machine with compressed air.Read the section Air Supply in the Safety Precautions chapter.
- Main air on/off valve
- Filter
- Filter-regulator, main air pressure
- Filter
- Pressure switch
- Pressure gauge, product tank cleaning
- Safety valve
- Regulator, product tank cleaning
- Adjustment screw
Valid for MecmanThe main pneumatic unit supplies units in the filling machine with compressed air.Read the Section Air Supply in the Safety Precautions chapter.
- Regulator, main air pressure
- Pressure gauge, main air pressure
- Soft start valve A66K0209
- Pressure switch A66B0200
- Regulator, product tank cleaning V51T1033
- Pressure gauge, product tank cleaning
- Filter 40µ V68V1211
- Filter 8µ
- Filter, V68V2211
Pneumatic Supply - Set Pressure
| Equipment Status | Program Step |
Valid for FestoSet the air pressure according to the table. To set the pressure switch, follow the instructions.| Position | Main function | Pressure kPa (bar) |
| (1) | Main air pressure | 630 (6.3) |
| (2) | Pressure switch | 530 (5.3) |
| (3) | Tank cleaning pressure | 50 (0.5) |

The positions correspond to the positions in the table
- Regulator, main air pressure
- Pressure switch
- Regulator, product tank cleaning
Set Pressure Switch - Valid for Festo
General- The pressure guard is controlled by the following buttons.

- Edit button
- Up-button
- Down-button
Change Settings- Press the edit button to access the setting menus. Every push of the edit button shows a new menu. The settings will be saved when leaving a menu.
- When all the setting menus have been shown, the pressure guard returns to showing the run mode menu.
- Use the up and down buttons to set the pressure guard according to the setting.
| Symbol | Setting | Description |
| Out A | Select | Switching Output A |
| _l¯ | Select | Threshold comparator |
| [SP] | 6.3 bar | Switching pressure (maybe necessary to set a lower value depending on the air supply on the factory) |
| [HY] | 1.0 bar | Hysteresis |
| [NO] | Select | Normally open contact |
- When using the setting values described in the table, the upper limit value is 6.3 bar, the lower limit value is 5.3 bar.
Valid for Mecman- Set the air pressure according to the table. To set the pressure switch, follow the instructions.
| Position | Main function | Pressure kPa (bar) |
| (1) and (2) | Main air pressure | 630 (6.3) |
| (3) | Pressure switch | 530 (5.3) |
| (4) and (5) | Tank cleaning pressure | 50 (0.5) |

The positions correspond to the positions in the table
- Regulator, main air pressure
- Pressure gauge, main air pressure
- Pressure switch
- Regulator, product tank cleaning
- Pressure gauge, product tank cleaning
Set Pressure Switch
The following procedure is easier to perform with two service engineers.- Open the door to the filling section electrical cabinet. Locate the I/O module and the channel status indicator (the 0 (zero) LED) for the pressure switch using the EM.
- Regulate the Regulator, main air pressure until the Pressure gauge, main air pressure reads 530 kPa.
- Turn the adjustment plate on the until the 0 (zero) LED is not lit.
- Set the Regulator, main air pressure to 630 kPa. The 0 (zero) LED lights yellow.
- Close the door to the electrical cabinet.
- If the alarm
Low air pressure is visible on the TPOP, reset it. 
- I/O module
- Regulator, main air pressure
- Pressure gauge, main air pressure
- Pressure switch A66B0200
- Low air pressure, TPOP alarm
Pneumatic Supply - Change Filter Inserts
| Equipment Status | Air must be turn OFF. Program Step |
Risk of personal injury.Pressurised machinery. The system must be depressurised before cleaning.
Valid for Festo- Shut off the air supply by turning the Shut-off valve to the right.Note: It is possible to lock all the valves if necessary.
- Press the Button on the Regulator (A66R0255) downwards.
- Turn the Filter bowl to the left, and pull gently downwards.

- Shut-off valve
- Regulator (A66R0255)
- Button
- Filter bowl
- Turn the Filter plate to the left.
- Remove the Filter plate and the Filter.
Risk of damage to the equipment.A cleaned filter gets clogged much quicker than a new filter. It is recommended to change the filter instead of cleaning it.
Change the filter or clean it with water (max. 60 °C (140 °F)), soap suds, or petroleum ether (free of compounds). Risk of personal injury.Pressurised machinery. The filter bowl must be turned fully to the right into the body before pressurising the unit.
Attach the filter plate, and turn it to the right.Note: Only hold the clean filter at the lower end.- Attach the Filter bowl. Make sure that the Locking pin points towards the large Recess in the housing.
- Turn the Filter bowl to the right until you hear a clicking sound.

- Filter bowl
- Filter plate
- Filter
- Locking pin
- Recess
Valid for Mecman- Close the Main valve for the compressed air, and check that the Pressure gauge, main pressure and the Pressure gauge, product tank cleaning show zero.
- Remove the Cover.
- Unscrew the Cup, and remove the O-ring.
- Replace the Filter insert and holder.
- Replace the O-ring, and refit the Cup and the Cover.
- Open the Main valve.
- Step the machine up to air on, and check for leakage. Tighten if required.Note: The filters are provided with automatic drainage.

- Main valve
- Pressure gauge, main pressure
- Pressure gauge, product tank cleaning
- Cover
- Cup
- O-ring
- Filter insert and holder
Pneumatic Supply - Change Filter Inserts
| Equipment Status | Air must be turn OFF. Program Step |
- Close the Main valve for the compressed air, and check that the Pressure gauge, main pressure and Pressure gauge, product tank cleaning show zero.
- Remove the Filter housing by removing the four Screw with an allen key.
- Remove the Holder, the Washer, and the Filter insert. Make sure not to drop the Air distributor as it will become loose.
- Replace the Filter insert, and refit the assembly.
- Refit the Filter housing, and open the Main valve.
- Step the machine up to air on, and check for leakage. Tighten if required.Note: The filters are provided with automatic drainage.

- Main valve
- Pressure gauge, main pressure
- Pressure gauge, product tank cleaning
- Filter housing
- Screw
- Holder
- Filter insert
- Washer
- Air distributor
Pneumatic Supply - Set Soft Start
The Adjustment screw must be set according to the size of the pneumatic system to be pressurised.To set the Adjustment screw to a standard setting, see the following instruction.- Turn the Adjustment screw, as far as it will go in the to the right.
- Turn the Adjustment screw 10 full turns to the left.

- Adjustment screw
Pneumatic Supply - Troubleshooting
Two LEDs on top of the safe air valve indicate the operating status of the valve.| LED Power (green) | LED Error (red) | Status |
| Off | Off | Operating voltage not applied |
| Lights and remains lit for 6 seconds | Lights and remains litfor 6 seconds | The safety air valve is running through startup tests |
| Blinking on and off | Off | The safety valve is in an exhaust status |
| Lights and remains lit | Off | The safety valve is in a pressurised status |
| Quickly flashes four times | Flashes in one-second pulses | Error code: Count the number of red flashes and see the table below |
Error codes| Number of red flashes | Error type | Possible cause | Action |
| 6 | Pneumatic | Missing external Air Supply, or manual valve on ramp is closed during power-up | Secure external air supply, and open manual valve on ramp |
| 8 | Electrical | Faulty electrical connection | Connect according to electrical drawings |
| All other numbers | Internal fault | | Try to resolve the problem by changing the NECA connection box. If that does not resolve the problem, change the safety air valve |
Restart Loop in the PLC ProgramIf, for some reason, the machine has been stepped up to Air On with the manual valve closed before the safety air valve, or air pressure is missing for other reasons, the safety air valve will go in to a fault mode (Error Code 6 red flash). The TPOP will give an air supply alarm. For Safety Air Valves in Carton Section, Package Section (or ASU with NR12)- Open the door where the safety air valve is placed.
- Open the manual valve, or correct the missing air problem.
- Close the door, and acknowledge the alarm (for ASU with NR12 ,push the reset button). The PLC program will then restart the faulted safety air valve.
For Main Safety Valve (on the Filling Section)- Step down the machine to Air Off.
- Open the manual valve, or correct the missing air problem.
- Step up to Air On again.
Functional Description
Note: The ice water cooling of the product tank is disconnected for the machine variant AW.The ice water that flows through the TT/3 ice water system is supplied by the customer's external ice water system. The TT/3 must be supplied with a flow of 85l/min and the ice water must have a temperature of 1 to 7˚C (33.8 to 44.6 °F). The flow and temperature are both measured and logged by the TT/3.The ice water circulates through the HEPA cabinets and the cooling mantle of the product tank before it returns to the customer's external ice water system. The HEPA cabinets must be continually cooled with ice water to ensure a high hygienic level. The mantle of the product tank is only filled from program step tank filling to program step production end. During these program steps, the cooling effect keeps the product in the tank cool.When a CIP or SIP is performed on the TT/3, the ice water shall not be on in the mantle. If the ice water is on, the rapid heating during these procedures can cause problems with expanding steam and water. To avoid these problems, the ice water is pumped out from the mantle and returned to the customer's external ice water system. By pumping the ice water back to the external ice water system, there is also no waste.When the ice water is removed from the mantle of the product tank, it is first collected in the Water tank. When the water tank is full, the Pump starts up and returns the ice water to the external ice water system. When the level in the Water tank is low, the pump stops again.
- Water tank
- Pump
Trouble shooting 110305711/110305712
DescriptionWhen the ice water is removed from the mantle of the product tank it is first collected in the Water tank. When the water tank is full the Pump starts up and return the ice water to the external ice water system. When the level in the Water tank is low the pump stops again.Conditions to set the alarmIf the Pump runs continually for more than 60 seconds or if it starts and stops more than 15 times when draining the Water tank the yellow alarm 110305711/110305712 occurs.Trouble shooting- Make sure that all the valves are functioning correctly and are in the correct position.
- Make sure that the pump is running correctly.
- Make sure that the level probes in the Water tank are functioning and are correctly set.
- Make sure that the level relay is correctly set. The conductivity of the ice water media has an effect on the sensitivity of the system.- If the Pump runs continually for more than 60 seconds the R-value probably needs to be increased according to Level Control Relay - Set or Level Control Relay - Set.- If the Pump starts and stops more than 15 times when draining the Water tank the R-value probably needs to be decreased according to Level Control Relay - Set or Level Control Relay - Set.

- Water tank
- Pump
Ice Water Flow Meter - Change the Sensor Unit
| Equipment Status | Power must be turn OFF. Program Step |
- Disconnect the electrical cables.
- Loosen the Lock screw.
- Remove the old Sensor unit by turning and lifting it away from the Paddle wheel unit.
- Attach the new Sensor unit.
- Tighten the Lock screw.
- Connect the electrical cables.

- Lock screw
- Sensor unit
- Paddle wheel unit
Ice Water Thermocouple - Change the Thermocouple
| Equipment Status | Power must be turn OFF. Program Step |
Hazardous voltage.The main power supply disconnector must be switched off and secured with a lock before starting any work on the thermocouple.Will shock, burn or cause death.
Ice water.Make sure that the pipeline is drained before you do any work on the flow meter.The pipeline that the flow meter is connected to may be full of very cold water.
- Disconnect the Connection.
- Remove the Bolt.
- Change the Thermocouple.
- Fasten the Thermocouple with the Bolt.
- Connect the Connection.

- Connection
- Bolt
- Thermocouple
Ice Water- Change Level Sensor
| Equipment Status | Program Step |
- Remove the Nut and the Cable.
- Loosen the Bracket and lift out the Level sensor.
- Remove the Nut and the Bracket.
- Change the Level sensor.
- Assemble in the reverse order.

- Nut
- Cable
- Bracket
- Level sensor
- Nut
Ice Water- Change Non-return valve
| Equipment Status | Program Step |
- Remove the Pipe with the connection.
- Remove the Non-return valve.
- Install the new Non-return valve.
- Assemble in the reverse order.

- Pipe
- Non-return valve
Ice Water - Change Vent valve
| Equipment Status | Program Step |
- Remove the Pipe and the connection.
- Remove the Vent valve.
- Change the Vent valve.
- Assemble in the reverse order.

- Pipe
- Vent valve
Ice Water Pump - Change Air outlet
| Equipment Status | Program Step |
- Hold the Coupling with a wrench and turn the Air outlet counter-clockwise.
- Remove the Air outlet.
- Install the new Air outlet while holding the Coupling with a wrench.

- Coupling
- Air outlet
Granulate Hopper - Set Proximity Switch
| Equipment Status | Program Step |
Basic setting
Set the gap according to the illustration below.During production
Check that the signals are received, during the suction intervals, from both the proximity switches (the LED at the rear side of the proximity switches are to light up).Note: The signal from one of the proximity switches is for the Granulate Supply Units (hatch function). The signal from the other proximity switch is for the alarm.Granulate Hopper - Change Inlet Gasket
| Equipment Status | Program Step |
- Loosen the Connection clamp.
- Disconnect the Suction pipe.
- Remove the Screw and the Lid.
- Loosen the Nut and change the Gasket.
- Tighten the Nut.
- Assemble the Lid and tighten the Screw.
- Connect the Suction pipe and check the earth cable is applied across the pipe connection.

- Connection clamp
- Suction pipe
- Screw
- Lid
- Nut
- Gasket
Granulate Hopper - Change Hatch Gasket
| Equipment Status | Program Step STEP ZERO |
| Consumables | Adhesive Gel: TP No. 344436-0000 Type P 100 Emery cloth |
Hygiene risk.Make sure that no contamination from grinding or polishing enters the granulate hopper.Grinding and polishing can contaminate the master batch.
- Grind off all remnants of old glue from the Seal seat with type P 100 emery cloth.
- Roughen all contacts surfaces on the Seal seat as well as on the Gasket.
- Clean the contact surfaces with spirit and let them dry.
- Apply adhesive gel on the contact surfaces of the gasket (only on the gasket).
- Press the gasket against the seal seat to make it stick and then press the Hatch hard against the seal for two minutes. Thereafter apply a pressure (place a heavy object) on the hatch during the drying period.
- Clean the hopper thoroughly.Note: The adhesive gel attains full strength after 12 hours.

- Seal seat
- Gasket
- Hatch
Functional Description
The logger is part of the Installation to Performance (ITP) system.The main function of the ITP system is to make sure that the different supply parameters to the machine are within the specified limits. The machine will only work at maximum efficiency if these specifications are met. Measured ParametersThe measured supply systems are:| Supply system: | Measured parameters: |
| CIP | Return flow on side 1Return flow on side 2Return pressure on side 1Return pressure on side 2 |
| Ice water | Inlet flowInlet temperature |
| Product | Pressure on side 1Pressure on side 2 |
| Steam | Steam pressure |
All of these measured parameters are continually recorded on a logger. This log can be used both on the logger itself and on a computer for more detailed analysis.AlarmsIf the measured parameters are outside of the specified limits, a blue or yellow alarm will be triggered. These alarms mean that something inside or outside of the machine must be corrected.The alarm levels have been set so that the machine will function at maximum efficiency. If the specified parameters are not followed, the machine will malfunction and require more downtime.The alarm levels are:| Media | Specification* | Alarm limit | Hystes | Time delay | Enable source | Alarm |
| Product Pressure Side 1 | 20-80kPa | >400 kPa | 10 kPa | 0 sec | none** | Blue (information) |
| Product Pressure Side 2 | 20-80kPa | >400 kPa | 10 kPa | 0 sec | none** | Blue (information) |
| Ice Water Temperature | 1-7 °C | >8 °C | 0 °C | 120 sec | none** | Blue (information) |
| Ice Water Flow | 85 l/m | <50 l/m | 0 l/m | 120 sec | none** | Blue (information) |
| Steam Pressure U400 | 350-1000 kPa | <340 kPa | 10 kPa | 0 sec | none** | Yellow in SIP (machine steps to zero).Blue in other machine steps (information). |
| Steam Pressure U405 | 110-120 kPa | <100 kPa | 0 kPa | 900 sec | none** | Yellow in SIP (machine steps to zero).Blue in other machine steps (information). |
| Difference in steam pressure between V404 and V405 | | >80 kPa | 0 kPa | 0 sec | none** | Yellow in SIP (machine steps to zero).Blue in other machine steps (information). |
| CIP Return Flow Side 1 | 15-16 m3/h | <13 m3/h | 0 m3/h | 20 sec | Machine in CIP Side 1Product Pressure Side 1 >50 kPa in > 10 sec. | Blue (information) |
| CIP Return Flow Side 2 | 15-16 m3/h | <13 m3/h | 0 m3/h | 20 sec | Machine in CIP Side 2Product Pressure Side 2 >50 kPa in > 10 sec. | Blue (information) |
| CIP Return Pressure Side 1 | | >100 kPa | 1 kPa | 0 sec | Machine in CIP Side 1 | Blue (information) |
| CIP Return Pressure Side 2 | | >100 kPa | 1 kPa | 0 sec | Machine in CIP Side 2 | |
* These levels can also be found in the IM** none = always onITP Hardware
- CIP flow meter (side 1 and 2)
- CIP pressure gauge (side 1 and 2)
- Ice water temperature meter
- Product pressure switch (side 1 and 2)
- Steam pressure gauge and flow measuring
ITP LoggerThe ITP logger is situated in the filling section electrical cabinet and records all of the measured parameters on its memory card. This memory card has enough room to record continually for 15 months. The log from the ITP logger can be used to diagnose the supply systems and to find the cause of any alarms that may occur. This diagnosis becomes much easier if you move the log files from the memory card to a computer, where you can use an add-in for Microsoft Excel to present the data in several different ways.Logger - Set a Name For The Logger
| Equipment Status | Program Step |
- Press the Menu key to open the
Operator menu. - Press the Down key once to step to the
Configuration option. - Press the Enter key to accept the
Configuration option. - Press the Enter key to accept
Operator 1. - Press the Enter key when the logger asks for a password to open the
Operator 1 window.Note: There is no password for the logger and the text box must be empty when you press the Enter key. - Press the Enter key to accept
Edit Current Configuration and to open the System Configuration window. - Press the Menu key to open the
Operator menu. - Press the Down key once to step to the
Common option. 
- Down key
- Enter key
- Up key
- Press the Enter key to accept the
Common option and to open the Common Configuration window. - Press the Down key five times to step to the
Instrument tag option. - Press the Enter key to accept the
Instrument tag option. - Use the Down key to step to and highlight the Del option.
- Press the Enter key several times to delete the text in the Text box.
- Enter the number of your machine with underscores before and after the number. For example, if the machine number is M200011 your enter: "_M200011_". Use the following method:
- Use the Down key and the Up key to step to and highlight a number, letter or symbol.
- Use the Enter key to enter a highlighted number, letter or symbol.
- To enter the underscores “_”, step to the Next symbol set option and press the Enter key. You need to do this twice to step to the symbol set with the underscore.

- Del option
- Text box
- Next symbol set option
- OK option
- Use the Down key and the Up key to step to the
Ok option. - Press the Enter key to accept the new logger name.
- Press the Menu key to open the
Operator menu. - Use the Down key and the Up key to step to
Exit. - Press the Enter key to accept.
- Press the Enter key to accept the
Save As Current Configuration choice. - Press the Enter key to choose
Internal Storage and to save the new logger name.
Logger - Remove the Memory Card
| Equipment Status | Program Step |
Fragile material.Never bend the memory card.The material of the memory card is brittle and it will brake if it is bent.
Damage from static electricity.Remove any static energy by touching a grounded metal object before you touch the memory card. Never touch the gold connectors on the card. Static electricity can damage the memory card.
Take the memory card off-line
- Push the Menu key to open the menu.
- Use the Down key or Up key to step to the
setup option. - Push theEnter key to select
setup. - Use the Down key or Up key to step to the
off-line option. - Push the Enter key to select the
Off-line option. - Make sure that the Memory card icon changes colour from green to grey.

- Down key
- Up key
- Enter key
- Memory card icon
Remove the memory card from the logger
Light sensitive material.Never place the card in direct sunlight.Direct sunlight can destroy the memory card.
- Unlock the Memory card door with the Key.
- Press the Release catch and open the Memory card door.
- Remove the Memory card.
- Place the Memory card in an anti-static case when it is not in use.
- Close the Memory card door.

- Memory card door
- Key
- Release catch
- Memory card
Logger - Install the Memory Card
| Equipment Status | Program Step |
| Special Equipment | Soft clean cloth |
Fragile material.Never bend the memory card.The material of the memory card is brittle and it will brake if it is bent.
Damage from static electricity.Remove any static energy by touching a grounded metal object before you touch the memory card. Never touch the gold connectors on the card.Static electricity can damage the memory card.
Install the memory card in the logger
- Unlock the Memory card door with the Key.
- Press the Release catch and open the Memory card door.
- Clean the gold connectors on the Memory card with a soft clean cloth.
- Carefully insert the Memory card into the logger.
- Close the Memory card door.

- Memory card door
- Key
- Release catch
- Memory card
Bring the memory card on-line
Note: The memory card will go on-line automatically after a few seconds. If not, do the procedure below.- If the logger never has had an on-line memory card, you have to upload the configuration file from the memory card before you can bring the memory card on-line. Do this according to Logger - Upload The Configuration From The Memory Card to The Logger.
- Push the Menu key to open the menu.
- Use the Down key or Up key to step to the
setup option. - Push the Enter key to select
setup. - Use the Down key or Up key to step to the
on-line option. - Push the Enter key to select the
On-line option. - Make sure that the Memory card icon changes colour from grey to green.

- Down key
- Up key
- Enter key
- Memory card icon
Logger - Load Data from The Memory Card to a PC
| Special Equipment | PC Compact Flash card reader |
- Place the memory card in the memory card reader of the PC.
- Use the explorer to open the memory card drive on the PC.Note: Do not open the SM1000 files.
- Copy the folder named SM1000 from the memory card to a suitable location on the PC.
- Eject the memory card from the PC.
Logger - Install Datamanager Software on the PC
| Equipment Status | |
| Special Equipment | PC Datamanager software |
Install
- Insert the Datamanager installation CD into the CD-drive.Note: You may be able to find a later version of the software on the ABB homepage.
- Click
Install DataManager Software (Excel 2000, 2002, 2003 & XP). - Click
Next. - Choose
I accept the terms in the license agreement and click Next.
- Enter a
User Name and a Organization and click Next. - Click
Next to accept the installation folder. - Click
Next to start the installation.Note: The installation may take a few minutes. Go to the next step when the program is installed. - Read the text in the window and then click Next.
- Click
Finish to finish the installation.
Activate
- Start Microsoft Excel.
- Select
Add-ins in the Tools menu to open the Add-in window. - Select
Datamanager by checking the checkbox next to it. If Datamanager can not be selected from the list, do step m) to n).
- Click
Browse and navigate to: Program Files\Microsoft Office\Office\Library. - Double-click on the Datamanager Add-in file. The add-in will now be activated in Microsoft Excel.
- Click
ok in the Add-in window. A new Datamanager tool bar appears in Microsoft Excel.
Logger - Open and view Data in Microsoft Excel
| Equipment Status | |
| Special Equipment | PC Datamanager software |
- Open Microsoft Excel.
- Click Open Binary File .
- Click Browse....
- Browse to where you placed the binary files from the logger card.
- Choose the binary file that you want to open and click
Open. - If you want to open more than one file at the same time, click the next
Browse... and do step d) to e) again. You can open up to 12 files at a time. - Check the Check box next to the file or files that you want to open.
- Set the time span of the files that you want to open with the Start time slide bar and End time slide bar. Only the time between the start and end time will be shown when you open the file.
- Click Create spreadsheet .

- Open Binary File
- Browse...
- Check box
- Start time slide bar
- End time slide bar
- Create spreadsheet
- Click View chart.
- Choose a start and end time in the
Chart Data Selection window. - Click Ok to create a graphic chart of the data.

- View chart
- Ok
Logger - View Historical Data on the Logger
Entering the Historical Data View
- Press the Menu key to open the
Operator menu. - Use the Down key to step to the
Historical Review option. - Press the Enter key to accept the
Historical Review option.Note: A Line will appear on the screen. This Line on the graph shows the time when the Values were measured. - Press the Menu key to open the
Operator menu. - Use the Down key to step to the
Screen interval option. - Press the Enter key to accept the
Screen interval option.Note: The Screen interval options set how long a time interval that is shown on the screen. If you set it to one hour, all the measured values for one hour will be shown. This does not control how far back in time you can check the values.
Choose a time interval by using the following method:- Use the Up key and the Down key to step to the time interval that you want to use.
- Press the Enter key to select a time interval.

- Down key
- Enter key
- Line
- Values
- Up key
- Use the Down key and the Up key to step backward and forward in the graph to find the event in the graph that you want to look closer at.Note: A large time interval can be used to find the event that you want to look at faster. Then when you have found it you can zoom in on the event by setting the screen to a smaller time interval.
Exiting the Historical Data View
- Press the Menu key to open the
Operator menu. - Use the Down key to step to the
Historical Review option. - Press the Enter key to accept the
Historical Review option. - Use the Down key to step to the
Exit option. - Press the Enter key to accept the
Exit option.Note: The time interval will be reset to the value that is defined in the configuration of the logger.
Logger - Upload The Configuration From The Memory Card to The Logger
- Press the Menu key to open the
Operator menu. - Press the Down key once to step to the
Configuration option. - Press the Enter key to accept the
Configuration option. - Press the Enter key to accept
Operator 1. - Press the Enter key when the logger asks for a password to open the
Operator 1 window.Note: There is no password for the logger and the text box must be empty when you press the enter button (3). - Press the Down key once to step to
Open a Configuration. - Press the Enter key to open the
Internal Storage window. - Press the View key to toggle to
external storage. 
- Down key
- Enter key
- View key
- Up key
- Use the Down key and the Up key to find the configuration file
2000_config_XX.cfg.Note: XX stands for the version of the configuration file. Always use the configuration file with the highest version number if there are more than one to choose from. - Press the Enter key to accept the configuration file and to open the
System Configuration window. - Press theMenu key to open the
Operator menu. - Use the Down key and the Up key to step to
Exit. - Press theEnter key to accept.
- Press the Enter key to accept the
Save As Current Configuration choice. - Press the Enter key to choose Yes.
- Press the Enter key to choose
Internal Storage and to save the new configuration.
Logger - Calibrate the Thermocouple Signal
| Equipment Status | Program Step |
| Special Equipment | Calibrator Fluke TP No. 90458-0914 Cable (5 m) to Fluke TP No. 90458-0915 |
- Set the fluke, see Procedure Logger - Set the Fluke 714.
- Remove the Connection from the Thermocouple.
- Connect the Cable from the fluke to the Thermocouple.
- Read the measured temperature from the display on the fluke.

- Connection
- Thermocouple
- Cable
- Press the Menu key on the logger to open the
Operator menu. - Press the Down key once to step to the
Configuration option. - Press the Enter key to accept the
Configuration option. - Press the Enter key to accept
Operator 1. - Press the Enter key when the logger asks for a password to open the
Operator 1 window.Note: There is no password for the logger and the text box must be empty when you press the Enter key. - Press the Down key four times to step to the
Disable recording in configuration check box. - Press the Enter key to uncheck the
Disable recording in configuration check box. - Press the Up key four times to step to the
Edit Current Configuration option. 
- Down key
- Enter key
- Up key
- Right key
- Left key
- Press the Enter key to accept
Edit Current Configuration and to open the System Configuration window. - Press the Menu key to open the
Operator menu. - Use the Down key to step to the
I/O modules option. - Press the Enter key to accept the
I/O modules option. - Press the Right key (8) to step to the
B:Analog I/P tab. - Use the Down key and the Up key to step to the
B3 channel that needs to be calibrated. - Press the Enter key to enter the edit window for the selected channel.
- Use the Down key to step to the
Offset adjust option. - Press the Enter key to enter the edit window for the
Offset adjust option. - Enter the positive or negative value that is needed to calibrate the logger to show the correct measured value from item d). For example: if the measured value is 10 and the logger shows 12, enter -2. Use the following method:
- Use the Down key, Up key, Right key and the Left key to step to and highlight a number, or symbol.
- Use the Enter key to enter a highlighted number or symbol.
- Use the Enter key to accept the total value when you have entered all the numbers that you need and to close the edit window.
- Use the Down key to step to the
Ok option. - Press the Enter key to accept the
Ok option. - Press the Menu key to open the
Operator menu. - Press the Down key once to step to the
Exit option. - Press the Enter key to accept.
- Press the Enter key to accept the
Save As Current Configuration choice. - Press the Enter key to choose
Yes. - Press the Enter key to choose
Internal Storage and to save the calibration. - Remove the fluke Cable from the Thermocouple.
- Connect the Connection to the Thermocouple.
Functional Description
The logger is part of the Installation to Performance (ITP) system.The main function of the ITP system is to make sure that the different supply parameters to the machine are within the specified limits. The machine will only work at maximum efficiency if these specifications are met. Measured ParametersThe measured supply systems are:| Supply system: | Measured parameters: |
| CIP | Return flow on side 1Return flow on side 2Return pressure on side 1Return pressure on side 2 |
| Ice water | Inlet flowInlet temperature |
| Product | Pressure on side 1Pressure on side 2 |
| Steam | Steam pressure |
All of these measured parameters are continually recorded on a logger. This log can be used both on the logger itself and on a computer for more detailed analysis.AlarmsIf the measured parameters are outside of the specified limits, a blue or yellow alarm will be triggered. These alarms mean that something inside or outside of the machine must be corrected.The alarm levels have been set so that the machine will function at maximum efficiency. If the specified parameters are not followed, the machine will malfunction and require more downtime.The alarm levels are:| Media | Specification* | Alarm limit | Hystes | Time delay | Enable source | Alarm |
| Product Pressure Side 1 | 20-80kPa | >400 kPa | 10 kPa | 0 sec | none** | Blue (information) |
| Product Pressure Side 2 | 20-80kPa | >400 kPa | 10 kPa | 0 sec | none** | Blue (information) |
| Ice Water Temperature | 1-7 °C | >8 °C | 0 °C | 120 sec | none** | Blue (information) |
| Ice Water Flow | 85 l/m | <50 l/m | 0 l/m | 120 sec | none** | Blue (information) |
| Steam Pressure U400 | 350-1000 kPa | <340 kPa | 10 kPa | 0 sec | none** | Yellow in SIP (machine steps to zero).Blue in other machine steps (information). |
| Steam Pressure U405 | 110-120 kPa | <100 kPa | 0 kPa | 900 sec | none** | Yellow in SIP (machine steps to zero).Blue in other machine steps (information). |
| Difference in steam pressure between V404 and V405 | | >80 kPa | 0 kPa | 0 sec | none** | Yellow in SIP (machine steps to zero).Blue in other machine steps (information). |
| CIP Return Flow Side 1 | 15-16 m3/h | <13 m3/h | 0 m3/h | 20 sec | Machine in CIP Side 1Product Pressure Side 1 >50 kPa in > 10 sec. | Blue (information) |
| CIP Return Flow Side 2 | 15-16 m3/h | <13 m3/h | 0 m3/h | 20 sec | Machine in CIP Side 2Product Pressure Side 2 >50 kPa in > 10 sec. | Blue (information) |
| CIP Return Pressure Side 1 | | >100 kPa | 1 kPa | 0 sec | Machine in CIP Side 1 | Blue (information) |
| CIP Return Pressure Side 2 | | >100 kPa | 1 kPa | 0 sec | Machine in CIP Side 2 | |
* These levels can also be found in the IM** none = always onITP Hardware
- CIP flow meter (side 1 and 2)
- CIP pressure gauge (side 1 and 2)
- Ice water temperature meter
- Product pressure switch (side 1 and 2)
- Steam pressure gauge and flow measuring
ITP LoggerThe ITP logger is situated in the filling section electrical cabinet and records all of the measured parameters on its memory card. This memory card has enough room to record continually for 15 months. The log from the ITP logger can be used to diagnose the supply systems and to find the cause of any alarms that may occur. This diagnosis becomes much easier if you move the log files from the memory card to a computer, where you can use an add-in for Microsoft Excel to present the data in several different ways.Logger - Set a Name For The Logger
| Equipment Status | Program Step |
- Press the Main menu to display the
Operator menu. - Press the Configuration in the
Operator menu. - Press the Confirm and then the Confirm.Note: There is no password for the logger and the Text box must be empty when pressing the Confirm.


Main menu buttonConfiguration iconConfirm buttonConfirm button- Text box
- Enter the
Tag menu by pressing in sequence the: - Enter the machine number with underscores before and after the number in the Text box. For example, if the machine number is M20011 enter: _M20011_ and press the Confirm button.
- Press the Return/Cancel button and Return/Cancel button.

Edit Configuration buttonCommon iconEdit button- Text box
Confirm buttonReturn/Cancel buttonReturn/Cancel button
- Press the Apply Changes button and then the Confirm button.
- Save the configuration file.

Apply Changes buttonConfirm button
Logger - Remove the Memory Card
| Equipment Status | Program Step |
Fragile material.Never bend the memory card.The material of the memory card is brittle and it will brake if it is bent.
Damage from static electricity.Remove any static energy by touching a grounded metal object before you touch the memory card. Never touch the gold connectors on the card. Static electricity can damage the memory card.
Take the memory card off-line
- Press the Main menu button to display the
Operator menu. - Press the Logging icon in the
Operator menu. - Press the Off-line icon in the
Logging menu. - Make sure that the
Archive media icon changes status to off-line. 
Main menu buttonLogging iconOff-line icon- Archive media online (green)
- Archive media offline (grey)
Remove the memory card from the logger
Light sensitive material.Never place the card in direct sunlight.Direct sunlight can destroy the memory card.
- Press down the Release catch and open the Door.Note: Make sure that the Archiving active indicator light is not lit ( do not remove media when lit).
- Remove the Memory card.
- Place the Memory card in an anti-static case when it is not in use.
- Close the Door.

- Release catch
- Door
- Archiving active indicator light
- Memory card
Logger - Install the Memory Card
| Equipment Status | Program Step |
| Special Equipment | Soft clean cloth |
Fragile material.Never bend the memory card.The material of the memory card is brittle and it will brake if it is bent.
Damage from static electricity.Remove any static energy by touching a grounded metal object before you touch the memory card. Never touch the gold connectors on the card.Static electricity can damage the memory card.
Install the memory card in the logger
- Press down the Release catch and open the Door.
- Clean the gold connectors on the Memory card with a soft clean cloth.
- Carefully insert the Memory card into the logger.
- Close the Door.

- Release catch
- Door
- Memory card
Bring the memory card on-line
Note: The memory card will go on-line automatically after a few seconds. If not, do the procedure below.- If the logger never has had an on-line memory card, you have to upload the configuration file from the memory card before you can bring the memory card on-line. Do this according to Logger - Upload The Configuration From The Memory Card to The Logger.
- Press the Main menu button to display the
Operator menu. - Press the Logging icon in the
Operator menu. - Press the On-line icon in the
Logging menu. - Make sure that the
Archive media icon changes status to off-line. 
Main menu buttonLogging iconOn-line icon- Archive media online (green)
- Archive media offline (grey)
Logger - Load Data from The Memory Card to a PC
| Equipment Status | |
| Special Equipment | PC Compact Flash card reader |
- Place the memory card in the memory card reader of the PC.
- Use the explorer to open the memory card drive on the PC.Note: Do not open the RVG200 files.
- Copy the folder named RVG200 from the memory card to a suitable location on the PC.
- Eject the memory card from the PC.
Logger - Install Datamanager Software on the PC
| Special Equipment | PC Datamanager software |
Install
- Insert the Datamanager installation CD into the CD-drive.Note: You may be able to find a later version of the software on the ABB homepage.
- Click the
setup.exe application.
- Click the
Next button.
- Select installation folder and click the
Next button.
- Confirm the installation and click the
Next button to start the installation.
- When the installation is complete click the
Close button to exit.
- Start the
DataManager by double-click symbol on the screen.
Logger - View Historical Data on the Logger
Entering the Historical Data View
- Press the Main menu button to display the
Operator menu. - Press the Historical Review icon in the
Operator menu. - Press the Enter/Exit icon in the
Historical Review menu.Note: A Cursor will appear on the screen. This Cursor on the graph shows the time when the Values were measured. To move forward and backward through the recorded data, press the Top right or Bottom right corners of the chart.
Main menu buttonHistorical Review iconEnter/Exit iconHistorical review active icon- Cursor
- Values
- Top right
- Bottom right
- Press the Main menu button to open the
Operator menu. - Press the Screen Interval icon to open the
Screen interval menu.Note: The Screen interval options set how long a time interval that is shown on the screen. If you set it to one hour, all the measured values for one hour will be shown. This does not control how far back in time you can check the values. - Use the Up button or the Down button to select a screen interval in the Item list.
- Press the Confirm button to accept the screen interval.

- Main menu button
Screen Interval iconUp buttonDown button- Item list
Confirm button
Exiting the Historical Data View
- Press the Main menu button to open the
Operator menu. - Press the Historical Review icon.
- Press the Enter/Exit icon.Note: The time interval will be reset to the value that is defined in the configuration of the logger.

- Main menu button
- Historical Review icon
- Enter/Exit icon
Logger - Calibrate the Thermocouple Signal
| Equipment Status | Program Step |
| Special Equipment | Calibrator Fluke TP No. 90458-0914 Cable (5 m) to Fluke TP No. 90458-0915 |
- Set the Fluke. See Procedure Logger - Set the Fluke 714.
- Remove the Connection from the Thermocouple.
- Connect the Cable from the Fluke to the Thermocouple.
- Read the measured temperature from the display on the Fluke.

- Connection
- Thermocouple
- Cable

Fluke
- Press the Main menu button to display the
Operator menu. - Press the Configuration icon in the
Operator menu. - Press the Confirm button and then the Confirm button.Note: There is no password for the logger and the Text box must be empty when pressing the Confirm button.


Main menu buttonConfiguration iconConfirm buttonConfirm button- Text box
- Enter a calibration value by pressing in sequence the:

Edit Configuration buttonI/O iconB:Analog I/P iconInput B3 tabEdit buttonEdit button- Text box
Confirm button

Fluke
- Accept the offset adjusting by pressing the:

Confirm buttonReturn/Cancel buttonReturn/Cancel buttonReturn/Cancel buttonApply Changes button
- Remove the Fluke Cable from the Thermocouple.
- Connect the Connection to the Thermocouple.
Recorder - Load Configuration Data
| Equipment Status | Program Step step zero |
| Special Equipment | Laptop PC Communication Cable RS 232-C CompactFlash reader |
Loading via Serial Interface
Note: For detailed information, see the manual supplied on the JUMO installation disk.- Open the Cover and connect the serial communication cable supplied with the recorder between the laptop PC and the Setup plug on the front of the recorder.
- Start the setup program Logoscreen CF.

- Cover
- Setup plug
Note: If there has never been any previous communication with a device, the “Assistant for Device Settings” will automatically be started when the first attempt at communication is made.- Insert the software USB key into a laptop PC USB port.Note: If a software CD has been supplied, insert the software CD into the laptop PC CD drive.
- Locate the folder JUMO Recorder and copy the relevant file (3274962-xxxx for ASD and AW, 3609837-xxxx for XH and XHIC) to the PC desktop.
- Establish a connection between the laptop PC and the recorder by clicking on the Establish connection button.
- Select the recorder in the device list and click the Connection button.

- Establish connection button
- Connection button
- Click on the Open button and locate the configuration file and then open the file.
- Click on the Data transfer to device button to upload the new recorder configuration settings.

- Open button
- Data transfer to device button
- Rotate the Control knob to access the Device manager and press the Control knob.
- Select Audit trail by rotating and pressing the Control knob.
- Check that the New configuration is reported on the log of all the user actions.
- Close the setup program Logoscreen CF and disconnect the communication cable.

- Control knob
- Device manager
- Audit trail
- New configuration
Loading from CompactFlash Card
Note: For detailed information, see the manual supplied on the JUMO installation disk.- From the software USB key, copy the configuration file for the recorder (3274962-xxxx for ASD and AW, 3609837-xxxx for XH and XHIC) into the CompactFlash memory card (Using a CompactFlash card reader/writer, not supplied).
- Perform the log in as “Master” to access the CompactFlash Card functions, see Recorder - Log-in.
- Open the Cover and insert the CompactFlash memory card with the configuration data into the CompactFlash slot. The Memory manager window is displayed.

- Cover
- CompactFlash slot
- Rotate the Control knob to select CF card -> Config data.
- Press the Control knob to upload the new recorder configuration settings.
- When the new recorder configuration settings have been uploaded the recorder performs an automatic reset.Note: Do not remove the CompactFlash memory card while the upload is in progress.

- Control knob
- CF card -> Config data
- Rotate the Control knob to select Secure remove of hardware and press the Control knob. When the Hardware can be removed message appears, the CompactFlash memory card can be ejected.
- Close the Cover.

- Cover
- Control knob
- Secure remove of hardware
- Hardware can be removed
- Rotate the Control knob to access the Device manager and press the Control knob.
- Select Audit trail by rotating and pressing the Control knob
- Check that the New configuration is reported on the log of all the user actions.

- Control knob
- Device manager
- Audit trail
- New configuration
Loading from USB Pen Drive
Note: For detailed information, see the manual supplied on the JUMO installation disk.- From the software USB key, copy the relevant file (3274962-xxxx for ASD and AW, 3609837-xxxx for XH and XHIC) into another USB pen drive.
- Perform the log in as “Master” to access the CompactFlash Card functions, see Recorder - Log-in.
- Open the Cover and insert the USB pen drive in the USB host. The Flash Manager menu is displayed.

- Cover
- USB host
- Memory manager window
- Rotate the Reading configuration from USB Flash drive to select OK icon.
- Press the Reading configuration from USB Flash drive to upload the new recorder configuration settings.
- When the new recorder configuration settings have been uploaded the recorder performs an automatic reset.Note: Do not remove the USB pen drive while the upload is in progress.

- Control knob
- USB stick -> Config data
- Rotate the Reading configuration from USB Flash drive to select Secure remove of hardware and press the Reading configuration from USB Flash drive. When the Hardware can be removedmessage appears, the USB pen drive can be removed.
- Close the Cover.

- Cover
- Reading configuration from USB Flash drive
- Secure remove of hardware
- Hardware can be removed
- Rotate the Reading configuration from USB Flash drive to access the Device manager and press the Reading configuration from USB Flash drive.
- Select Audit trail by rotating and pressing the Reading configuration from USB Flash drive
- Check that the New configuration is reported on the log of all the user actions.

- Reading configuration from USB Flash drive
- Device manager
- Audit trail
- New configuration
Recorder - Export Data
| Equipment Status | Program Step |
- Log in to the recorder according to Recorder - Log-in.
- Open the lower recorder door and insert the USB-stick or CE-card into the recorder.
- In the window that opens, step to the Backup -> USB-Stick or Backup -> CE-card option by rotating the Control knob.
- Press the Control knob to select the option.
- When the data has been exported, step to the Remove the hardware safely by rotating the Control knob.
- Press the Control knob to select the Remove the hardware safely.
- Log out.

- Control knob
Recorder - Upload settings
| Equipment Status | Program Step |
- Log in to the recorder according to Recorder - Log-in.
- Open the lower recorder door and insert the USB-stick or CE-card with the settings into the recorder.
- In the window that opens, step to the USB-stick -> Config. data or CE-card -> Config. data option by rotating the Control knob.
- Press the Control knob to select the option.
- When the settings have been uploaded, step to the Remove the hardware safely option by rotating the Control knob.
- Press the Control knob to select the Remove the hardware safely.
- Log out.

- Control knob
Recorder - Printing Records
- Insert the CompactFlash card into a CF reader or a USB-drive into the computer that has the Jumo PCA software installed.
- Start the Jumo PCA 3000 software.
- If this is the first time that the software is being used for the password; enter 9200 with the user ID of Master.
- From the
Archive menu, select Read in data.
- Find the Folder for the data source in order to read in the data.Note: The files in the folder will not be shown.
- Set the Target folder for the data.Note: When you do the calibration you make note of the time that it was accomplished. This will be where you can get that chart for that period of time.

- Folder for the data source
- Target folder
- Once you read in the data to your target folder you will have the message Data have been read in successfully!
- Click the Open button and the chart appears.

Open button
- Open the chart and put your mouse cursor on the end of your temperature line. All of the data that you need to show the calibration will appear. Do a Print Screen with your computer, in order to get the graph and the data that is showing.
- In order to get an analog print out to accompany the graph from the
File menu, select Print Preview, and then click the Analog button. 
Analog button
- Select
All data sets and then click the OK button. 
OK button
- You now have the analog data to go along with your chart. You can circle by hand and initial the time of calibration.
Note: Each channel must be done. Everything that is on the chart recorder must be printed in this manner. When all of the information is printed attach the printouts to the Calibration Report and put it in the CVP.- The calibration is now complete.
Recorder - Description
Analogue Channels
| Channel Number | Type | Colour | Description |
| AN1 | Analogue | Blue | Evaporator temp hydrogen peroxide HC side1:Deviations cause an alarm level 28 machine stop (indicated on channel DI2 Operational Parameters). |
| AN2 | Analogue | Blue | Evaporator temp hydrogen peroxide HC side2:Deviations cause an alarm level 29 machine stop (indicated on channel DI5 Operational Parameters). |
| AN3 | Analogue | Brown | Peroxide reducer temp side1:Deviations cause an alarm level 28 machine stop (indicated on channel DI2 Operational Parameters). |
| AN4 | Analogue | Brown | Peroxide reducer temp side2:Deviations cause an alarm level 29 machine stop (indicated on channel DI5 Operational Parameters). |
| AN5 | Analogue | Black | Pressure HEPA filter side1:Deviations cause an alarm level 23 machine stop (indicated on channel DI1 Operational Parameters). |
| AN6 | Analogue | Black | Pressure HEPA filter side2:Deviations cause an alarm level 24 machine stop (indicated on channel DI4 Operational Parameters). |
| AN7 | Analogue | Green | Evaporator temp hydrogen peroxide pre-treatment side1 (ASD and AW only):Deviations cause an alarm level 26 machine stop (indicated on channel DI2 Operational Parameters). |
| AN8 | Analogue | Green | Evaporator temp hydrogen peroxide pre-treatment side2 (ASD and AW only):Deviations cause an alarm level 27 machine stop (indicated on channel DI5 Operational Parameters). |
| AN9 | Analogue | Purple | SIP temperature indicating thermocouple side1:Deviations cause an alarm level 18 machine stop. |
| AN10 | Analogue | Purple | SIP temperature indicating thermocouple side2:Deviations cause an alarm level 19 machine stop. |
Digital Channels
| Channel Number | Type | Colour | Description |
| DI1 | Digital | Purple | Hygienic parameter Side1: This channel records the Side 1 alarms listed under 2.3.1.1 Normal Stop With Forced CIP and SIP (Valid for USA/Canada Version) in the TeM Process Description.Normal Position: Thin Line Alarm Position: Thick Line for 5 minutes after reset of the event alarm. Sterilization Complete: Thick Line for 30seconds after sterilization complete. Deviations cause a machine stop. |
| DI2 | Digital | Red | Operational parameter Side1: This channel records all Side 1 alarms that are not recorded on DI1, with the exception of the alarms listed in 2.2.9.1.4 Paused Production and Automatic Restart in the TeM Process Description. See 2.3.1.2 Safety Stop, 2.3.1.3 Quick Stop and 2.3.1.4 Normal Stop in the TeM Process Description for more information.Normal Position: Thin Line Alarm Position: In case of an event, the signal turns ON and remains ON for at least 30 seconds and until the operator has acknowledged the fault condition in the operator panel. Deviations cause a machine stop. |
| DI3 | Digital | Black | Production Side1: Production: Thick Line No production: Thin Line Deviations cause a machine stop. |
| DI4 | Digital | Purple | Hygienic parameter Side2: This channel records the Side 2 alarms listed under 2.3.1.1 Normal Stop With Forced CIP and SIP (Valid for USA/Canada Version) in the TeM Process Description.Normal Position: Thin Line Alarm Position: In case of an event, the signal turns ON and remains ON for at least 30 seconds and until the operator has acknowledged the fault condition in the operator panel. Sterilization Complete: Thick Line for 30seconds after sterilization complete. Deviations cause a machine stop. |
| DI5 | Digital | Red | Operational parameter Side2: This channel records all Side 2 alarms that are not recorded on DI1, with the exception of the alarms listed in 2.2.9.1.4 Paused Production and Automatic Restart in the TeM Process Description. See 2.3.1.2 Safety Stop, 2.3.1.3 Quick Stop and 2.3.1.4 Normal Stop in the TeM Process Description for more information.Normal Position: Thin Line Alarm Position: Thick Line for 5 minutes after reset of the event alarm. Deviations cause a machine stop. |
| DI6 | Digital | Black | Production Side2: Production: Thick Line No production: Thin Line Deviations cause a machine stop. |
| DI7 | Digital | Green | Gas clogged alarm Side1: Normal Position: Thin LineAlarm Position: Thick LineDeviations cause an alarm level 8 machine stop. |
| DI8 | Digital | Green | Gas clogged alarm Side2: Normal Position: Thin LineAlarm Position: Thick LineDeviations cause an alarm level 9 machine stop. |
| DI9 | Digital | Blue | Hygiene Chamber Cleaning/Disinfection Side1:Not active: Thin LineActive: Thick Line |
| DI10 | Digital | Blue | Hygiene Chamber Cleaning/Disinfection Side2:Not active: Thin LineActive: Thick Line |
Display and Controls
The resistive Touch screen allows the user to configure and operate the recorder almost intuitively, via a menu system icon-based. The Alarm LED (red) is lit continuously if an alarm is pending. The Power LED (green) flashes after switching on the device until the startup process is completed and then it is permanently lit .The USB host interface in the front (with cover) can be used to connect at USB memory stick for data exchange (measurement data, configuration data, user lists) between the recorder and the PC. Another USB device interface in the back can be used for communication with the setup program or PCC (PCA Communication Software).
- Touch screen
- Alarm LED
- Power LED
- USB host interface
The Status bar displays information as diagram type, group number, Logon status icon and the Time. Each area of the Status bar is an active button that can be used to access, by tapping on it, additional informations as the alarm list, weekday, user name and memory usage. The Status bar is also used as an alarm display, with the alarm text that is displayed alternately with a red background.The Navigation bar contains the buttons to access the main menu, the alarm menu, the visualization options and the screen navigation arrow.
- Status bar
- Navigation bar
- Logon status icon
- Time
Navigation Bar
Visualization Menu
Touch the Visualization menu icon. The view mode and group that should be currently displayed on the device are selected. Up to 6 analog channels and 6 digital channels of a group can be shown on one screen.In the Display option list, select the mode to display the recorded channels.The Curve Diagram view mode shows the analog and digital signals configured for the relevant group as Analog curves or Digital traces. The Channel informations as channel name, pointer and current value are shown in the lower part of the screen.Note: The curve diagram may be displayed vertically or horizontally.
Vertical and horizontal diagrams shown
Curve Diagram view mode- Digital traces
- Analog curves
- Channel informations
In the Digital diagram view mode the digital signals configured for the relevant group are displayed as digital traces.In the Bar graph view mode the analog signals configured for the relevant group are shown as bar graphs, and the digital signals as coloured areas or frames.In the Text image view mode the current values for the analog signals configured for the relevant group are shown as numbers.
Digital diagram view mode

Bar graph view mode and
Text image view mode
Digital diagram view modeBar graph view modeText image view mode
Recorder - Log On
| Equipment Status | Program Step step zero |
Note: For detailed information, see the manual supplied on the JUMO installation disk.- In the navigation bar touch the Main Menu icon.
- Touch the Log-In Menu icon and then the
Logon icon. 
Log-In Menu icon
- In the
Enter ID window, select the user and confirm with the OK icon.Note: The recorder is delivered by default with an internal user list which comprises several user ID’s. The user ID named Master allows full access to all the configuration parameters and the password is 9200. The users ID named User 1, User 2 or User 3 allows the download of the recorded data only and the password is 1, 2 or 3.Note: If the recorder has been configured with individual user ID’s, contact the administrator of the equipment for access to the recorder. - Enter the password with the keypad and confirm with the Ok button. In the status bar the Logon status icon shows that the user is logged in.

OK icon- Ok button
- Logon status icon
Recorder - Set Date, Time and Language
| Equipment Status | Program Step step zero |
Set Date and Time
Note: For detailed information, see the manual supplied on the JUMO installation disk.- Perform the log on as user “Master” to access the configuration functions, see Recorder - Log On.
- Touch the Main Menu icon and select the Parameterization icon.
- Select Date and time in the
Parameterization list. - Touch the Analog Input window to open the editing window for date and time and set date and time.
- Set the Daylight Saving Time and the Time zone.
- Touch the OK icon.
- Touch the Exit button to return to main menu. The recorder performs an automatic reset.

Main Menu icon- Current date and time field
Daylight Saving TimeTime zoneOK iconExit button
Set Language
- Perform the log in as user “Master” to access the configuration functions, see Recorder - Log On.
- Touch the Main Menu icon and select the Configuration icon.
- Select DEVICE in the
Configuration list. - Touch the Drop down icon in the Language field to display the list of the available languages.
- Select the desired language and touch the OK icon.
- Touch the Exit button to return to main menu. The recorder performs an automatic reset.Note: The new language is displayed after the automatic reset.

Main Menu iconConfiguration icon- Drop down icon
OK iconExit button
Recorder - Load Configuration Data
| Equipment Status | Program Step step zero |
| Special Equipment | Laptop PC USB Flash Drive |
Note: For detailed information, see the manual supplied on the JUMO installation disk.- From the software USB key, select the correct folder where the configuration file
KONF323.set is located.Note: Select the correct folder depending on machine variant AD or XH. - Copy the configuration file
KONF323.set into another USB pen drive.
- Perform the log in as user Master to access the Flash Manager functions, see Recorder - Log On.
- Open the Cover and insert the USB pen drive in the USB host. The Flash Manager menu automatically opens when the USB device is plugged in.

- Cover
Flash Manager menu
Risk of data loss due to software update.A software update deletes all recorded data stored on the device. Before updating the software, back up the recorded data on a USB flash drive.
- Select Saving all recording data on USB flash drive (Backup) and touch the OK icon. All recorded data available on the device (including previously backed up data) is transferred to the USB flash drive (data backup). This function can take up to 30 minutes to be completed.

- Saving all recording data on USB flash drive (Backup)
OK icon
Risk of data loss.Do not remove the USB flash drive without ejecting it. Do not remove the USB flash drive until the message is displayed.
- Select Reading configuration from USB Flash drive and touch the OK icon. The configuration data is transferred from the USB flash drive to the device. This re-configures the device and data recording is restarted.
- When the new recorder configuration settings have been uploaded the recorder performs an automatic reset.Note: Do not remove the USB pen drive while the upload is in progress.
- Select Logging off USB flash drive to safely remove the USB flash drive to avoid data loss.

- OK icon
- Reading configuration from USB Flash drive
- Logging off USB flash drive
Recorder - Calibrate
| Equipment Status | Program Step step zero |
Note: For detailed information, see the manual supplied on the JUMO installation disk.It is possible to compensate for false signals received by the recorder, such as systematic errors in the signals sent from thermocouples. For example, if a thermocouple indicates a temperature value which is consistently 5 °C less than the true temperature at the lower end of its reading range and 10 °C less, at the higher end of its reading range, this can be corrected by the recorder.- Perform the log on as user “Master” to access the configuration functions, see Recorder - Log On.
- Touch the Main Menu icon and select the Parameterization icon.
- Select FINE ADJUSTMENTS in the
Parameterization list. - Select the analog input to be corrected (e.g. Analog Input 1). The Analog Input window is displayed.
- Touch the Active field to select Yes and to activate the fine adjusting function.
- Touch the Value field to be adjusted and set the new value in the keypad displayed.
- Touch the OK icon.
- Touch the Exit icon to return to the main menu. The recorder is automatically reset.

Main Menu iconAnalog Input windowActive field- Value field
OK iconExit icon
Recorder - Set IP Address
| Equipment Status | Program Step step zero |
- Perform the log in as user “Master” to access the configuration functions, see Recorder - Log On.
- Touch the Main Menu icon and select the Configuration icon.

Main Menu iconConfiguration icon
- Select the Ethernet icon in the
Configuration list. - Open the Drop down icon and select the option Manually in the IP Address assignment field.
- Enter the network parameters according to the table.
| IP address | 192.168.1.225 |
| Subnet mask | 255.255.255.0 |
| Standard gateway | 192.168.1.1 |
| DNS server | 0.0.0.0 |
- Touch the OK icon.
- Touch the Exit button to return to main menu.

Ethernet icon- Drop down icon
OK iconExit button
Description
This chapter contains the maintenance procedures for the Electrical System. The Functional Description on page Functional Description provides a technical overview of the functions included in the Electrical System.Note: If the TPOP is restarted when the distribution equipment is switched off, the NRG logger may not work. It can also happen if the distribution equipment is restarted, lost power or in some way lost communication with the TPOP. If the NRG logger is not working, make sure the distribution equipment is switched on, and restart the TPOP.Service Functions
Safety HazardAlways reset all the functions and make sure that the machine is cleaned and sterilised before using the machine to produce packages.The service functions bypass safeguards that have been put in place to ensure that the machine is run safely and that the packages that are produced are safe and hygienic for the consumer.

The service function window contains several functions that will help you when servicing the machine. To reach it you turn the service key and to leave it you reset the key.The functions in this window are meant to be used during service and it is very important that the machine is reset and cleaned before it is used in production again.It is possible to leave the service function window at any time while the service key is turned. To return to the window you press the service function symbol that appears over the ladder. This symbol will always be shown as long as a service function is being used.To use a function you click the field that you want to use and then use the buttons that appear to toggle between active and inactive.
| 1 | Reset CIP/SIP PLC Program – This function is used to terminate and reset the PLC program if the program has locked up or not been completed properly.It is absolutely forbidden to use this function for service purposes or to stop a running CIP/SIP process. |
| 2 | Reg. Valve – This function is used when you service the regulator valve.The regulator valve can not be disassembled unless it is fully open. This function opens the valve. |
| 3 | Interlock SIP & Tankfilling – It is normally not possible to step up to Tankfilling without first doing a SIP, or perform a SIP without first doing a CIP.This function resets and sets the interlock between the Tankfilling /SIP and SIP/CIP . After the service function has been reset, a CIP is forced by the machine. |

| 4 | Override tank Level – During service it is often necessary to run packages through the machine but it is not always possible to get product or water to the filling tank. This function makes the machine think that it has a full tank and you can then step up the machine and produce empty packages. |
| 5 | Package section – This function brings up the service window for the package section. |
| 6 | Volume change – This function aborts a volume change and can be used if a problem occurs during one. |

| 7 | Override DE – During service it can be necessary to run the machine without running the DE equipment that it is connected to. This function makes it possible to run the machine only, without the DE equipment starting up. |
| 8 | Water Test - Particulate Filling Only. This function is used to load parameters, more suitable for filling water, to the filling system for test purpose. |
| 9 | LFU – This function brings up the service window for the LFU. |
| 10 | TTCU PLC Program – This function is used to terminate and reset the PLC program if the program has locked up or not been properly completed.It is absolutely forbidden to use this function for service purposes or to stop a running TTCU process. After the function has been reset the machine will not force the operator to run a new hygiene chamber cleaning sequence. It is important that this is done |
| 11 | Pipe Drain – This function drains the return pump and the pipes above the pump that are used during hygiene cleaning. |
Activated Functions Logged as Events in PLMS| Event code | Event description |
| 110035200 | Service key activated |
| 110036291 | CIP interlock disactivated, S1 |
| 110036301 | SIP interlock disactivated, S1 |
| 110036311 | Regulating valve forced open, S1 |
| 110036321 | Interlock SIP / Tank filling override, S1 |
| 110036322 | Interlock SIP / Tank filling override, S2 |
| 110036292 | CIP interlock disactivated, S2 |
| 110036302 | SIP interlock disactivated, S2 |
| 110036312 | Regulating valve forced open, S2 |
| 110036322 | Interlock SIP / Tank filling override, S |
| 110036320 | Reset TTCU |
Electrical Cabinets
There are three electrical cabinets in the TT/3 machine. The main electrical cabinet contains the main part of the electrical equipment and control components on the machine. The electrical cabinet in the ASU contains electrical equipment for the ASU.The electrical cabinet in the filling section contains electrical equipment for the filling section.There is also a connection box in the CSU and electrical cabinets in the GSU and in the TTCU.Servo System
The servo drives execute the movement of all servomotors on the machine. It is connected to the PLC by a Sercos network.Control System
The two PLC (Logic and Motion) controls all functions on the machine, for example sensors, valves, actuators, indicators and motors.TPOP and PLMS
The TPOP display is the HMI (human machine interface) of the machine and it is situated in the doors on both sides of the carton section.The TPOP computer is situated in the electrical cabinet and controls the HMI (human machine interface) and the PLMS data logging. It is connected to the PLC by an Ethernet network.Distributed I/O
The DeviceNet connects all distributed I/O on the machine and transfers the status and commands to and from the PLC.Safety system
The safety system controls the SAFE shutdown of the machine if a door or emergency stop button is actuated.TMCC
The Tetra Pak Multi-purpose Compact Controller is a device that controls the bar code on the packaging material.Vision Unit
The vision system is used to detect screw caps that are not properly attached. The packages are scanned while passing the vision system on the conveyer. Overview

- TT/3 Main electrical cabinet
- TT/3 ASU electrical cabinet
- TT/3 Filling section electrical cabinet
- Connection box, CSU (Valid for variant XH with IC)
- Cabinet, GSU
- Cabinet, TTCU
- Cabinet, SRU(Valid for SRU Version 1 and Version 2)
Residual Current Device - Check
| Equipment Status | Power must be turn ON. Program Step Program Step Program Step |
Hazardous voltage.Change the residual current device if it does not function.Will shock, burn or cause death.
The Residual current device protects from electrical shock by interrupting the electric circuit to a load when a fault is detected. Check its function before using the socket outlet:Note: The power supply to the wall socket and the lighting, in the machine and in the electrical cabinet, will be shut off when the residual current device is checked.- Make sure that the switch is in Position ON.
- Press the T-button and observe the switch.
- The residual current device functions if the circuit breaker trips, and the switch jumps to Position OFF.
- If the circuit breaker does not trip immediately, turn off all supplies and change the residual current device.
- If the switch jumps to Position OFF, turn the switch back to Position ON and turn off the power supply disconnector.

- Residual current device
- Position ON
- T-button
- Position OFF

TT/3 Filling Machine
- Residual current device
- Socket outlet
- Power side
- Control side

Cap Supply Unit (
CSU) (Valid for variant
XH with
IC)
- Socket outlet
- Residual current device

Granulate Supply Unit (
GSU)
- Socket outlet
- Residual current device

Tetra Top Cleaning Unit (
TTCU)
- Socket outlet
- Residual current device
Wall Socket - Reset
| Equipment Status | Program Step |
- Press the Reset button to reset the Wall socket.

- Reset button
- Wall socket
Level Control Relay - Set
| Equipment Status | Power must be turn OFF.
|
Personnel Requirements.Only authorised and skilled personnel are allowed to change the parameters. Changing the parameters can affect the machine in unexpected ways.
The level control relay (RM22LA32MR) monitors the liquid level by measuring the change in the resistance of immersed and non immersed electrodes. The relay sensitivity must be set according to the conductivity of the liquid. On this relay, the Power supply indication LED are lit when the relay is in power ON condition. The Relay output status LED lights when the correct level is reached.Note: If the green LED dial pointers are blinking, the electrical supply must be turned OFF and ON.
- LEDPower supply indication
- LEDRelay output status
- Set the level regulator parameters using the potentiometers (Sensitivity potentiometer and Time delay control), and selectors (Configuration: selection of the operating mode and the sensitivity range. and Selection of the number of levels and the On/Off time delay).

- Configuration: selection of the operating mode and the sensitivity range.
- Sensitivity potentiometer
- Selection of the number of levels and the On/Off time delay
- Time delay control
- For a more detailed description of the potentiometers and selectors, see the following table.
Set the relays in the main cabinet as follows:
| Relay | Configuration (3) | Sensitivity (4) | Number of Levels (5) | Time Delay (6) |
| Cooler | A01K0004 | Empty/St | 35 | 1/ON Delay | 1 |
| Conductivity | A01K0005 | Empty/Hs | 20 | 1/ON Delay | 1 |
Set the relays in the filling cabinet as follows:
| Relay | Configuration (3) | Sensitivity (4) | Number of Level (5) | Time Delay (6) |
| Membrane | V60K3201 | Empty/St | 35 | 1/ON Delay | 1 |
| V60K4201 | Empty/St | 35 | 1/ON Delay | 1 |
| V60K5201 | Empty/St | 35 | 1/ON Delay | 1 |
| V60K6201 | Empty/St | 35 | 1/ON Delay | 1 |
| Resuction/Bottom Valve | V60K3202 | Empty/St | 35 | 1/ON Delay | 1 |
| V60K4202 | Empty/St | 35 | 1/ON Delay | 1 |
| V60K5202 | Empty/St | 35 | 1/ON Delay | 1 |
| V60K6202 | Empty/St | 35 | 1/ON Delay | 1 |
| Ice water (see note below) | A69B0227 | Empty/LS | 65 | 2/ON Delay | 0.1 |
If required, adjust with the potentiometer.The yellow LED lights up when the conductivity is too high.Note: Ice water sensitivity value: The value may have to be changed depending on the conductivity of different ice water media. The setting should be between 55 and 85.Overview

- Electrical cabinet
- Control side
- UV Side
- Fuse board
- Power side
- Motor control side
- Connection plate
- Ultra Sonic equipment
- Cooling Unit
Hazardous voltage.The power supply disconnector must be switched off and secured with a lock before maintenance inside the electrical cabinet.Will shock, burn, or cause death.
Cooling Unit - Change Filter
| Equipment Status | Power must be turn OFF.
|
| Consumables | Filter, TP no. 90459-0928 |
Risk of personal injury.Stay on the platform, inside the railing, or wear a shoulder harness when preforming this procedure.Falling from the machine can cause serious personal injury.
- Remove the lower Cover from the Cooling unit .
- Change the Filter inside the lower Cover.
- Assemble the Cover.

- Cover
- Cooling unit
- Filter
Functional Description
This describes the function on side 1. See the following translation table for side 2.| Side 1 | Side 2 | Function |
| V51K1004 | V51K2004 | Control unit |
| V51B1247 | V51B2247 | Shutter switch |
| V51Q1013 | V51Q2013 | Contactor (2 kW) |
| V51Q1014 | V51Q2014 | Contactor (2 kW) |
Condition during ignition phaseSince the shutter is closed when the lamp is to be ignited, there is only current going through one of the 2 kW ballast coils. This current is too small to ignite the UV-lamp. The lamp needs current from both ballast coils (4 kW) to be ignited. To make this possible when the shutter is closed, control unit V51K1004 is used.Function of control unit V51K1004During the ignition phase of the UV-lamp, the control unit V51K1004 bypasses the shutter switch V51B1247 and activates contactor V51Q1014 (V51K1004:9). Together, contactor V51Q1013 and control unit V51K1004 make it possible to deliver 4 kW power to the UV-lamp.During the ignition phase, when the intensity of the UV-lamp increases, control unit V51K1004 measures the increased voltage (V51K1004:6 and 7). When the voltage reaches a certain level, after about 10 to 20 seconds, control unit V51K1004 disconnects contactor V51Q1014. The UV-lamp power then goes down to 2 kW.The red LED on control unit V51K1004 is lit during the ignition phase when contactor V51Q1014 is activated. When the correct voltage is reached after about 10 to 20 seconds, the LED goes off and contactor V51Q1014 is deactivated.The ignition phase can also be observed by looking at the UV-lamp with the shutter closed.The UV-lamp will ignite and the intensity will increase during 10 to 20 seconds. The intensity will then drop when control unit V51K1004 disconnects contactor V51Q1014 and the UV-lamp power goes down to 2 kW.After the ignition phase, the regulation of 2 kW or 4 kW power to the UV-lamp is controlled by shutter switch V51B1247. See Section Normal Shutter Control.Setting control unit V51K1004Control unit V51K1004 is set by the manufacturer when delivered. Normally it does not need any adjustment. But, since there are manufacturing tolerances between UV-lamps, it might be necessary to adjust the control unit V51K1004. See Procedure 7.2.2.4-1 Control Unit, 3060 - Set UV-lamp Limit.Normal Shutter Control
When the UV lamp is on and contactor V51Q1013 is activated, for example, during motor running, the V51B1247 shutter contact inside the UV-housing hardware controls the power of the lamp (half or full power) by switching contactor V51Q1014 ON and OFF.Shutter closed: Only contactor V51Q1013 is activated, 2kW. The UV lamp is on half power.Shutter open: Contactor V51Q1014 is activated by hardware and adds 2kW to the 2kW from contactor V51Q1013. The UV lamp is on full power, 4kW.Control Unit, 3060 - Set UV-lamp Limit
| Equipment Status | Program Step |
| Special Equipment | Volt meter with TrueRMS |
This instruction is for side 1. See the following translation table for side 2.| Side 1 | Side 2 | Function |
| V51K1004 | V51K2004 | Control Unit |
| V51B1227 | V51B2227 | Shutter Switch |
| V51Q1013 | V51Q2013 | Contactor (2 kW) |
| V51Q1014 | V51Q2014 | Contactor (2 kW) |
| V51Q1017 | V51Q2017 | Contactor (1 kW) |
| V51M1245 (F/C V51T1032) | V51M2245 (F/C V51T2032) | Fan (Frequency convertor) |
| V51V1035 | V51V2035 | Ignitor |
Hazardous voltage.Be careful when measuring the voltage, and always measure the voltage when the lamp is already On. Never measure the voltage during the start of ignition.Will shock, burn or cause death. The UV system generates very high voltage in the start of the ignition phase, when going from lamp Off to lamp On, igniterV51V1035 sends more than 1000V.
- Turn on the UV lamp with the
Package Disinfection service function (See Chapter 2 Control Panels in the Operator Manual), or step the machine up to Motor On. - Make sure that the UV-lamp is on.
- Leave the lamp on for at least 3 minutes, check that the UV Cooling Fan V51M1245 (F/C V51T1032) is running.
- Open the shutter with the
Package Disinfection service function (see UV-lamp - Check Intensity), or override it in the PLC program. - Check that the UV light is on.
- Make sure that contactors V51Q1013 and V51Q1014 are activated (4 kW).
- Make sure that contactor V51Q1017 is not activated (5 kW).
- Check the voltage between igniter V51V1035:D and V51V1035:L2. This is the voltage over the lamp. The voltage must be approximately 290V TrueRMS.
- Close the shutter.
- The LED on the control unit must be off , and contactor V51Q1014 must be off. (The control unit controls contactor V51Q1014 during the lamp ignition phase). If they are not off, turn the potentiometer to the left until the LED is turned off and contactor V51Q1014 goes off.
- Wait for at least 3 minutes.
- Make a new measurement on the lamp voltage. It must be approximately 260V TrueRMS.
- Turn the Potentiometer on the control unit (V51K1004) to the right until the LED turns on, and then turn the potentiometer to the left approximately 4 to 5 turns. (1 turn is approximately 7V).

V51K1004Control unit, 3060
- Potentiometer
- LED
Functional Description
This describes the function on side 1. See the following translation table for side 2.| Side 1 | Side 2 | Function |
| V51R0002 | V51R0003 | Current Relay |
| V51Q1014 | V51Q2014 | Contactor (2 kW) |
There are two LEDs on the current relay V51R0002, one green and one yellow.The Green LED is lit when current relay V51R0002 is connected to power. The Yellow LED is lit when current through the relay is higher than the set-point value.The function of the current relay is to measure the current to UV-lamp when contactor V51Q1014 is engaged. When the contactor V51Q1014 is engaged, (shutter open or ignition phase) the Yellow LED is lit when the measured current is higher than the set-point value (I-value) and at the same time relay output is high (V51R0002:14).As soon as the contactor V51Q1014 is disengaged the Yellow LED turns off and relay output goes low.
- Yellow LED
- Green LED
Current Control Relay - Set
| Equipment Status | Power must be turn OFF.
|
- Disconnect and remove the current relays from the rail
- Set the current control relays (V51R0002 and V51R0003) as shown in the following table.
- Set the two Switch to underload and without memory according to the illustration. See the setting text (A to D) on each side of the current control relays.Note: It is necessary to have the power supply shut off to the current control relays when setting the switches. The new settings are only memorised during reboot.
- Put back and connect the current control relays.
- Turn the electrical supply disconnecting device to position I on.

V51R0002 Current control relayA=UnderloadC=With memoryB=OverloadD=Without memory
- T1
- I-value
- T2
- Hysteresis
- Switch
Digital Multi Circuit Protector - Set
| Equipment Status | Program Step step Zero |

| Number | Name | Function |
| 1 | Power input terminals (+V), (-V) | Connects to the input line. |
| 2 | Branch output terminals (+V), (-V) | Connects to the load lines.Up to four branch outputs can be connected. |
| 3 | Status indicators (red, green) | Indicates the connection and cut off status for each branch output.Cut off: Red. Connected: Green. |
| 4 | Tripping alarm output (+, -) | Output (transistor: OFF) when the error tripping operation functions. * |
| 5 | Alarm output (+. -) | Output (transistor: OFF) when a set value alarm detection is exceeded. * |
| 6 | Over-temperature output (+, -) | Output (transistor: OFF) when a set value for over-temperature detection is exceeded. * |
| 7 | External tripping input (+, -) | The tripping operation can be executed with an external input signal. |
| 8 | Seven-segment display (red) | Displays measured values and set values. |
| 9 | Unit indicators (orange) | V | Lit when the input voltage is being displayed. |
| A | Lit when the input current is being displayed.Flashes when the peak output current is being displayed. |
| kh | Lit when the run time is being displayed. |
| °C | Lit when the temperature is being displayed. |
| s | Lit when setting the sequence time. |
| 1 to 4 | Lit or flashing when displaying the branch output information. ** |
| 10 | Mode key | Used to change the parameter being displayed or to reset the peak hold current value. |
| 11 | Up key | Used to move to different setting modes or to increase a set value. |
| 12 | Down key | Used to move to different setting modes or to decrease a set value. |
| 13 | Reset key | Used when connecting branch outputs for tripping operations. *** |
| 14 | Communications terminals (RD, SD, SG) | Connects to the communication lines. (PS-232C). |
* Configured from independent circuits and either sinking or sourcing applications are possible.** Indicators 1 to 4 will not light exept when current is being displayed.*** Press for at least 3 s to enable operation.Note: The setting range is 0.5 to 3.8 A and the default value is 3.8. This default value must not be changed. The multi circuit protector is only meant for a 24 V DV load outside the main electrical cabinet and on the machine.Note: The first time that a multi circuit protector is connected it will enter the setting mode.- Press and hold the Up key and the down key at the same time for threeseconds to enter the mode selection menu.
- Use the Up key to step to Test Mode.
- Use the mode key to enter the Test Mode.
- Use the Up key and down key to select all four outputs.
- Use the mode key to set all the outputs to the ON position.
- Make sure that all four status indicators light up in green.
- Press and hold the Up key and the down key at the same time for threeseconds to enter the mode selection menu.
- Use the Up key to step to Run mode.
- Use the mode key to enter the Run mode.
Ultra Sonic Generator - Modify
| Equipment Status | Power must be turn OFF.
|
Note: The USG must be modified before it is used in the US/Canada version of the TT/3 filling machine.- Remove the Three phase fuse between the Ultra sonic generator and the Main filter.
- Remove the Fuse holder from the Ultra sonic generator.
- Plug the holes for the Fuse holder.
- Connect theMain supply source cable directly to the Main filter according to the lower diagram below.

The left diagram shows the unmodified configuration. The right diagram shows the modified configuration that is used for the US/Can version.
- Three phase fuse
- Ultra sonic generator
- Main filter
- Fuse holder
- Main supply source cable
Surge Protector - Change
| Equipment Status | Power must be turn OFF.
|
- When there is a voltage spike between neutral and protective earth, alarm 125320090 Surge Voltage Protector Released occurs. The Surge Protector is activated.
- Change the Surge Protector.

- Surge Protector
Functional Description
This cabinet is integrated in the ASU and is supplied with mains power from the main electrical cabinet.It contains electrical equipment for the ASU, such as frequency converters.Hazardous voltage.The power supply disconnector, situated on the main electrical cabinet, must be switched off and secured with a lock before maintenance inside the electrical cabinet.Will shock, burn, or cause death.
Note: The key to the lock must be removed by the technician and retained in his/her possession until all work is completed.For further information about DeviceNet see DeviceNet on page DeviceNet.Electrical Cabinet, Filling Section
Functional Description
This cabinet is integrated in the filling platform and is supplied with mains power from the main electrical cabinet.It contains electrical equipment for the filling section, such as frequency converter for fans and relays for tank level.Hazardous voltage.The power supply disconnector, situated on the main electrical cabinet, must be switched off and secured with a lock before maintenance inside the electrical cabinet.Will shock, burn, or cause death.
Note: The key to the lock must be removed by the technician and retained in his/her possession until all work is completed.For further information about DeviceNet see DeviceNet on page DeviceNet.Level controller see Control Unit (MUL-D2), page Control Unit (MUL-D2).Pressure switch see Level Control Relay, page Level Control Relay.Functional Description
The control unit converts a potentiometer position, that is the position of the product tank level sensor, into an analogue signal. The signal is sent to the PLC.For the ASCM variant the signal is also sent to the process (positive pump).
- Potentiometer input
- Analogue output (0/4 - 20 mA)
- Power supply 24 V DC 4 - 20 mA
Buttons
- The buttons,up and down, are used to change parameters and codes.
- The p is used to display parameters and confirm codes and settings.

- up
- down
- p
Control Unit (MUL-D2)- Set
| Equipment Status | Program Step |
Personnel Requirements.Only authorised and skilled personnel are allowed to change the parameters. Changing the parameters can affect the machine in unexpected ways.
- To access the parameter menu disconnect the two Power supply cable from number 9. Push and hold DOWN and P and, at the same time, connect the Power supply cable to number 9. The display shows software name and version and then code C100.
- Push up or DOWN to select code 131, push P to confirm.

- up
- DOWN
- P
- Power supply cable
- Pushup or DOWN to select AnLo, push P to confirm.
- Change the value from 0 to -24, push P to confirm.
- Pushup or DOWN to select AnSe, push P to confirm.
- Change the value from 1 to 0, push P to confirm.
- Push P for 3 seconds to return to the code list. Return to C100 and push P again to return to production.

- up
- DOWN
- P
- Power supply cable
Functional Description
The convertor module mirrors the analogue signal (Input 4-20mA, Output 4-20mA) from the control unit (MUL-D2) to the process to steer the positive pump.
- Power Supply 24 VDC
- Analogue output (0/4 – 20 mA)
- AI (4-20 mA)
- AI (4-20 mA)
Converter Module - Set
| Equipment Status | Program Step step zero |
Personnel Requirements.Only authorised and skilled personnel are allowed to change the parameters. Changing the parameters can affect the machine in unexpected ways.
Since the I to I (input 4-20 mA, output 4-20 mA) function is used the converter module must be opened before the configuration can be set up. See Chapter 4 Circuit Diagrams in the Electrical Manual for connections.- Press the two latches on either side and at the same time carefully pull the converter module out.
- Set the switches according to the table and illustration.
| S1 | S2 | S3 |
| Switch | State | Switch | State | Switch | State |
| 1 | ON | 1 | ON | 1 | OFF |
| 2 | ON | 2 | OFF | 2 | OFF |
| 3 | ON | 3 | OFF | 3 | ON |
| 4 | ON | 4 | ON | | |
| 5 | ON | 5 | ON | | |
| 6 | OFF | | | | |
| 7 | ON | | | | |
| 8 | OFF | | | | |
| 9 | OFF | | | | |
| 10 | OFF | | | | |
Filter Unit - Change Filter
| Equipment Status | Power must be turn OFF.
|
| Consumables | Consumable Filters, TP no. 315757-2700 |
- Open the Cover by pulling the blue handle upwards.
- Change the filter behind the cover.
- Close the Cover .

- Cover
Functional Description
This connection box is integrated in the CSU.It contains electrical equipment for the CSU, such as frequency converters for the fans and conveyors. The connection box in the CSU communicates with the main machine through Ethernet.Hazardous voltage.The power supply disconnector, situated on the main electrical cabinet, must be switched off and secured with a lock before maintenance inside the electrical cabinet.Will shock, burn, or cause death.
For information on how to set the frequency converters in the CSU see procedure Frequency Converter CSU - Set on page Frequency Converter CSU - Set.For more information about the CSU see CSU.Functional Description
This cabinet is integrated in the GSU. It contains electrical equipment for the GSU. The electrical cabinet in the GSU communicates with the main machine through digital inputs/outputs.Hazardous voltage.The power supply disconnector, situated on the main electrical cabinet, must be switched off and secured with a lock before maintenance inside the electrical cabinet.Will shock, burn, or cause death.
For more information about the GSU, see Granulate Supply Unit.Functional Description
This cabinet is integrated in the TTCU. It contains electrical equipment for the TTCU, such as frequency converters, point I/O nodes and a Pluto unit. The electrical cabinet in the TTCU communicates with the main machine through DeviceNet.Hazardous voltage.The power supply disconnector, situated on the main electrical cabinet, must be switched off and secured with a lock before maintenance inside the electrical cabinet.Will shock, burn, or cause death.
For information about the Pluto in the TTCU see Section Safety System.For information about the frequency converters see procedures in Section Distributed I/O.For more information about the TTCU, see chapter Tetra Top Cleaning Unit.Functional Description
The PLC system handles all functions for controlling the machine. The Logic CPU executes the logic functions of the machine, that is, stepping up and down and the actions of pneumatic actuators, alarms, and so on. The Motion CPU executes the parts in the machine concerning motion, that is, controlling the servomotors. The logic CPU and the motion CPU exchange information regarding ladder position, alarms, volume, and bottom format.Note: The NRG logger stops working if the communication between configured distribution equipment and TPOP breaks for some reason. For example, if:- TPOP is restarted when the distribution equipment is switched off.
- the distribution equipment is restarted.
- the distribution equipment loses power.
If this happens, make sure the configured distribution equipment is switched on, communication is re-established, and restart the TPOP. For instructions on how to check communication status, see Section PLMS NRG – DE Overview.
- PLC system
- CPULogic
- CPUMotion
Preparations for PLC Communication
Preparation for PLC Communication - Software Requirements
Preparation for PLC Communication - Install New Motor Database File
| Equipment Status | |
| Special Equipment | CD with machine software |
Install New Database Import Tool
Note: This section is only valid if the present version of Rockwell Database Import Tool is lower than version 2.0.0.7.- Uninstall the old version of
Rockwell Database Import Tool. - Install
Rockwell Database Import Tool, version 2.0.0.7, from the Machine Software TPOP CD.
Import Motion Database for Exlar
- Open the
Control Panel and then open Region and Language. 
- Region and Language
- In the Format drop-down list, select
English (United States). - Click on Additional settings.
- Make sure the Decimal Symbol is a dot and not a comma.
- Click OK.
- Format
- Additional settings
- Decimal Symbol
- OK
- Open the Start menu and select
All Programs / Rockwell Automation / Motion Database Tool. - Click on Import .cmf file.

- Import .cmf file
- Change the RSLogix Release to
V18 and Up. - Click on Browse and browse to the Machine Software TPOP CD.
- In the
Motion Database folder, select the file GX300602AB1258.cmf. - Click on Import.

- RSLogix Release
- Browse
- Import
- When the import is finished, the
Import History window pops up. Click Close. - Change back the
Format settings made in item Reference to Reference. 
- Close
Preparation for PLC Communication - Install EDS File
An EDS File, Electronic Data Sheet, is a simple text file that is used for identification of the product in the Rockwell Software programs.Already released products (products with a Tetra Pak 9xxxx-xxxx spare part number) may be delivered with new firmware revisions not installed on your computer. The Rockwell Software programs do not recognize it and will only show a question mark on that position. If so, you have to install a new EDS file with the same revision number as the product connected.Note: It is important that you are administrator on your computer, otherwise you will still have communication problems between RSLinx and the new device after EDS-installation.- Go to the Rockwell site: http://www.rockwellautomation.com/rockwellautomation/.
- Read the text and EDS Search Tips on the right.
- Search for the EDS file. The example below shows a search for an EDS file for a DNB scanner firmware revision 10.
- Find the EDS file for your product and click on the link in the
Details & Download column and save the file on your computer were you easily can find it during the installation. You may have to scroll down the list to find the correct file.
- Open the wizard for the EDS Hardware Installation Tool: .
- Click
Add.
- Select
Register a single file and click Browse... . If you have many EDS files in a folder you can select Register a directory of EDS files and they will all be registered at the same time. If your folder also includes subfolders containing EDS files, you also have to select Look in subfolders.
- Find the EDS file you saved on your computer and click
Open. If you use Register a directory of subfolders, select the folder.
- Click
Next>.
- Click
Next>.
- If you get a grey box instead of a graphic image you can change it to an icon. Select the grey box and click
Change icon. - Click
Next>.
- Click
Next>.
- Click
Finish.
- Click
Exit and restart your computer to make sure the installation has succeeded.
Preparation for PLC Communication - Assign Computer IP Address
| Equipment Status | Power must be turn ON.
|
| Special Equipment | CD with machine software |
- From Windows
Start menu, select: Settings / Network and Dial-up Connections / Local Area Connection. 
- Settings
- Network and Dial-up Connections
- Local Area Connection
- Select
Internet (TCP/IP) from the List. - Click Properties. The
TCP/IP dialogue box opens. - Select Use the following IP address.
- Type the IP address for the computer in the:

- List
- Properties
- Use the following IP address
- IP address field
- Subnet mask field
Preparation for PLC Communication - Configure RSLinx
| Equipment Status | |
| Special Equipment | CD with machine software |
The network card in the computer communicates with the filling machine by a programme called RSLinx through different networks such as Ethernet and DeviceNet. The network and IP addresses must be set in RSLinx.Note: If the computer has a Firewall program installed, this may need to be disabled every time the computer will be connected to the filling machine.- From the Windows
Start menu, select: 
- Programs
- Rockwell software
- RSLinx
- RSLinx
- Click Configure drives.
- Click the Drop down and select
Ethernet devices from the drop down menu. ClickAdd new. - Accept the default driver name by clicking
OK. - Type the Ethernet IP address in the new empty Host name field and then click Add new to add the next IP address.
| Description | IP address |
| Ethernet module A01K0029 in the CPU rack | 10.255.1.21 |
| Ethernet module A01K0011 in the expansion rack | 10.255.1.22 |
| Ethernet module in CSU (Valid for variant XH with IC) | 10.255.1.23 |
- ClickOK to save the configuration.

- Configure drives
- Drop down
- Add new
- Host name field
- Add new
- OK
Preparation for PLC Communication - Assign Address to Ethernet Module
| Equipment Status | Program Step |
| Special Equipment | Network cable |
The CPU Rack A01K0029 and the Expansion Rack A01K0011 communicates through Ethernet modules. New Ethernet modules has a MAC address programmed as factory setting. This MAC address must be changed to an IP address.Note: If the computer has a Firewall program installed, this may need to be disabled every time the computer is connected to the filling machine.- Connect the network cable between the computer and the network switch A01K0003.
- Make sure that the network cables between the switch and the Ethernet modules are connected.
- From the Windows
Start menu, select: 
- Programs
- Rockwell software
- RSLinx
- RSLinx
- Close the RSLinx program by selecting Exit and shutdown in the
File menu. 
- Exit and shutdown
- From the Windows
Start menu, select: 
- Program
- Rockwell software
- BOOTP DHCP server
- BOOTP DHCP server
If it is the first time the BOOT program is used it will ask for a network setting.Note: The Network Setting window can also be opened from the Tools menu in the BOOT program if a setting is necessary.- Type 255.255.0.0 in the Subnet Mask field. All other settings are 0.
- Click OK.

- Subnet Mask field
- OK
- After a while, if the program has contact with the Ethernet modules, the MAC addresses will be displayed in the Request history window. Make sure the addresses are the same as the displayed addresses on the displays of the Ethernet modules.
- Select a MAC address in the Request history window .
- Click Add to Relation List.

- Request history window
- Add to Relation List
- The MAC address is automatically filled in the MAC-address field. Type the new IP address in the IP address field. See the table below.
| Description | None address |
| Ethernet module A01K0029 in the CPU rack | 10.255.1.21 |
| Ethernet module A01K0011 in the expansion rack | 10.255.1.22 |
| Ethernet module in CSU (Valid for variant XH with IC) | 10.255.1.23 |
- Click OK. The new IP address will be displayed in the Request history window and on the displays of the Ethernet module.

- Request history window
- MAC-address field
- IP address field
- OK
- Select the Ethernet module relation in the Relation List window and then click Disable BOOTP/DHCP.
- Repeat steps Reference to Reference for the Ethernet module A01K0011.
- Open the doors of the power modules on the PLC rack. Turn the switches to the off position and wait a few seconds before turning them on again. Check to see if the Ethernet modules have received their new addresses, if not go back to step Reference.
- For the Ethernet module in the CSU additional settings must be preformed, see Additional Settings for the Ethernet Module in the CSU on page Additional Settings for the Ethernet Module in the CSU.
- Remove the straight through network cable between the computer and the network switch A01K0003.

- Relation List window
- BOOTP/DHCPDisable
Additional Settings for the Ethernet Module in the CSU
- Click on Properties for the cap supply unit Ethernet module.

- Properties
- Make sure that the Auto-Negotiate Port Speed and Duplex box under Port configuration is checked.

- Auto-Negotiate Port Speed and Duplex
- Port configuration
- Click Set Chassis Size in Module under Chassis Size.

- Set Chassis Size in Module
- Chassis Size
- Click Reset Module under Module Info to finish the setting.

- Reset Module
- Module Info
Preparation for PLC Communication - Ping Ethernet Modules
| Equipment Status | Program Step step zero |
| Special Equipment | Ethernet cable |
- Click Start and select Run....
- In the Run window, type cmd.

- Run...
- Run window
- In the CMD window, type ping and the IP address for the Ethernet module.
| Description | IP address |
| Ethernet module in TPOP | 10.255.1.0 |
| Ethernet module A01K0029 in the CPU rack | 10.255.1.21 |
| Ethernet module A01K0011 in the expansion rack | 10.255.1.22 |
| Ethernet module in CSU (Valid for variant XH with IC) | 10.255.1.23 |
| Ethernet module in Vision Unit S1 | 10.255.1.24 |
| Ethernet module in Vision Unit S2 | 10.255.1.25 |
| Ethernet module for Bottomvalves in PLC(Valid for variant ADY) | 10.255.1.40 |
| Ethernet module in Bottomvalve 1:1(Valid for variant ADY) | 10.255.1.41 |
| Ethernet module in Bottomvalve 1:2(Valid for variant ADY) | 10.255.1.42 |
| Ethernet module in Bottomvalve 2:1(Valid for variant ADY) | 10.255.1.43 |
| Ethernet module in Bottomvalve 2:2(Valid for variant ADY) | 10.255.1.44 |

- CMD window
- If a reply is received, the connection is working.
- If the text
Request timed out is displayed, check that
PLC
Note: Series mismatch! When replacing a component that contains firmware, it is important that the components have the same series as the old ones.Note: Revision mismatch! It might be possible to use a component with a new revision, but it is recommended to use the same revision as the old one.The series and revision is printed on the component.PLC Controller - Remove SD Card
| Equipment Status | Power must be turn OFF.
|
Risk of damage to the equipment.If you are not sure of the contents of the SD card, turn the key, in the mode switch of the PLC Controller, to the PROG position before you remove the card.Depending on the contents of the card, a power cycle or fault could cause the card to load a different project into the PLC Controller.
Note: Behind the cover of the Power Supply there is an on/off switch for the CPU rack.- Turn the Key to the PROG position.
- Open the Hatch on the PLC Controller.
- Press and release the SD card to eject it.
- Remove the SD card.
- Close the Hatch.

- Key
- Hatch
- PLC Controller
- SD card
PLC Controller - Change Energy Storage Module (ESM)
| Equipment Status | Program Step step zero |
- Remove the key from the Mode switch.
- Press down on the Release and pull the ESM away from the PLC Controller.
- Align the Slot of the new ESM and the PLC Controller.
- Slide the new ESM back until it snaps into place.

- Mode switch
- Release
- Slot
- ESM
PLC Controller - Change
| Equipment Status | Program Step step zero |
- Store the online project. See Procedure PLC Controller - Save the Online Project.
- Turn the TT/3 main power supply disconnector off.Note: Behind the cover of the Power Supply there is an on/off switch for the CPU rack.
- On the top and the bottom of the PLC Controller, press the locking tabs.
- Slide the PLC Controller out of the chassis.
- Install the SD card. See Procedure PLC Controller - Install SD Card.
Install the PLC Controller Into the Chassis
Note: Behind the cover of the Power Supply there is an on/off switch for the PLC Controller rack.- Insert the key into the PLC Controller.
- Turn the key to the REM position.
- Align the circuit board with the top and the bottom guides in the chassis
- Slide the module into the chassis. Make sure it is flush with the power supply or other modules and the that the top and bottom latches are engaged.
- Turn the TT/3 main power supply disconnector on.
- After a few minutes the PLC controller will be in run mode. The working order, of the start-up from the SD card, is:
- Checking the firmware. If it is wrong, the PLC Controller will be flashed with the correct firmware.
- Downloading the application program.
- Setting the PLC controller in run mode (remote only).
- Mode switch
- LEDRun
- LEDForce
- LEDSD
- LEDOk
Status of the PLC Controller
- Check the status of the PLC Controller. See Procedure PLC Controller - Status, on page PLC Controller - Status.
- Save the online project. See Procedure PLC Controller - Save the Online Project, on page PLC Controller - Save the Online Project.
PLC Controller - Save the Online Project
- Go online with the PLC Controller.
- Click
Save. - Click
Yes when the question Upload tag values before saving the project. appears.Note: If the wrong project is uploaded see .
Configure the Store Operation
- Put the PLC Controller in Program mode (REM Program or Program).
- On the
Online toolbar, click Controller properties. 
- Controller properties
- Select the
Nonvolatile Memory tab. - Click Load/Store.

- Load/Store
- Choose under what conditions to load the project back into the user memory (RAM) of the PLC Controller. In the Load Image field select
On Corrupt Memory and in the Load Mode field choose Run (Remote Only). - Type a note in the Image Note field that describes the project.
Store the Project
- Click Store .
- A dialogue box asks you to confirm the store.
- To store the project, click
Yes. - During storing, the following events occur:
- On the front of the PLC Controller, the OK LED displays the following sequence: flashing green, solid red, solid green.
- RSLogix 5000 software goes off-line.
- A dialogue box tells you that the storing is in progress.
- Click OK.Note: The storing operation may take up to 20 minutes even if RSLogix estimates it to take 3 minutes.When the storing is finished, you remain off-line.

- Store
PLC - Clear Major Fault
| Equipment Status | Program Step |
There are two ways of clearing a major fault in the PLC:With RSLogix 5000
- Go online with RSLogix 5000 software to get the fault code.
- Click on Controller properties.
- Select the Major Fault tab. If there is a major fault in the PLC the fault will be displayed in the Recent Faults box.
- To clear the faults click onClear Major and restart the program execution.

- Controller properties
- Major Fault tab
- Recent Faults box
- Clear Major
With the Keyswitch
If you do not have the possibility to connect to the system with RSLogix 5000 turn the Keyswitch in the following sequence:- PROG
- RUN
- PROGThe faults are cleared. Turn the key back to Run to start the PLC.

- Keyswitch
PLC Controller - Install SD Card
| Equipment Status | Power must be turn OFF.
|
Risk of damage to the equipment.If you are not sure of the contents of the SD card, turn the key, in the mode switch of the PLC Controller, to the PROG position before you install the card.Depending on the contents of the card, a power cycle or fault could cause the card to load a different project into the PLC Controller.
Note: Behind the cover of the Power Supply there is an on/off switch for the CPU rack.- Turn the Key to the PROG position.
- Open the Hatch.
- Insert the SD card into the SD card slot.
- Gently press the SD card until it clicks into place.
- Close the Hatch.
- Save the online project. See Procedure PLC Controller - Save the Online Project, on page PLC Controller - Save the Online Project.

- Key
- PLC Controller
- Hatch
- SD card
PLC Controller - Status
| Equipment Status | Program Step |
Status Indicators

- LEDOk
- LEDRun
- SD LED
- LEDForce
| Status Indicators |
| Indicator | Colour | Description |
| RUN | Off | The PLC Controller is in Program or Test mode. |
| Solid green | The PLC Controller is in Run mode. |
| FORCE | Off | No tags contain I/O force values. |
| Solid amber | I/O forces are active (enabled).I/O force values may or may not exist. |
| Flashing amber | One or more input or output addresses have been forced to an On or Off state, but the forces have not been enabled. |
| SD | Off | No activity is occurring with the SD card. |
| Flashing green | The controller is reading from or writing to the SD card.Do not remove the SD card while the controller is reading or writing. |
| Solid green | |
| Flashing red | The SD card does not have a valid file system. | |
| Solid red | The controller does not recognize the SD card. | |

- LEDOk
- LEDRun
- SD LED
- LEDForce
| Status Indicators |
| Indicator | Colour | Description |
| OK | Off | No power is applied. |
| Flashing red | If the PLC Controller is a new PLC Controller, then the PLC Controller requires a firmware update.If the PLC Controller is not a new PLC Controller, then a major fault has occurred.To clear the fault, either turn the keyswitch to PROG, then to RUN and then back to PROG again or go on-line with RSLogix 5000 software. |
| Solid red | - The controller is completing power-up diagnostics.
- The charge of the capacitor in the energy storage module is being discharged upon powerdown.
- The controller is powered, but is inoperable.
- The controller is loading a project to nonvolatile memory.
|
| Solid green | The PLC Controller is ok. |
General Status Messages
The messages that are described in the table are typically indicated upon powerup, powerdown, and while the PLC Controller is running to show the status of the controller and the energy status module.The messages are shown on the PLC Controller Display.
- Display
| General Status Messages |
| Message | Interpretation |
| No message is indicated | The controller is Off.Check the OK indicator to determine if the controller is powered and determine the state of the controller. |
| TEST | The controller is conducting power-up tests. |
| PASS | Power-up tests have been successfully completed. |
| SAVE | A project is being saved to the SD card.- removing the SD card.
- disconnecting power.
|
| LOAD | A project is being loaded from the SD card at controller powerup.- removing the SD card.
- disconnecting power.
- removing the energy storage module
|
| UPDT | A firmware upgrade is being conducted from the SD card upon powerup.If an update of the firmware upon powerup is not wanted, change the Load Image property of the controller. |
| CHRG | The capacitor-based energy storage module is being charged. |
| 1756-L7x/X | The controller catalog number and series. |
| Rev XX.xxx | The major and minor revision of the firmware of the controller. |
| No Project | No project is loaded on the controller.To load a project, do one of the following:- Use the Logix Designer application to download the project to the controller.
- Use a SD card to load a project to the controller.
|
| Project Name | The name of the project that is currently loaded on the controller. |
| BUSY | The I/O modules that are associated with the controller are not yet fully powered.Allow time for powerup and I/O module self-testing. |
| Corrupt Certificate Received | The security certificate that is associated with the firmware is corrupted. |
| ESM Not Present | An Energy Storage Module is not present and the controller cannot save the application at powerdown.Insert a compatible ESM, and, if using a capacitor-based ESM, do not remove power until the ESM is charged. |
| ESM Incompatible | The Energy Storage Module is incompatible with the memory size of the controller.Replace the incompatible ESM with a compatible ESM. |
| ESM Hardware Failure | A failure with the Energy Storage Module has occurred and the controller is incapable of saving of the program in the event of a powerdown.Replace the ESM before removing power to the controller so the controller program is saved. |
| ESM Energy Low | The capacitor-based Energy Storage Module does not have sufficient energy to enable the controller to save the program in the event of a powerdown.Replace the ESM. |
| ESM Charging | The capacitor-based Energy Storage Module is charging.Do not remove power until charging is complete. |
| Flash in Progress | A firmware upgrade initiated via ControlFLASH or AutoFlash utilities is in progress.Allow the firmware upgrade to complete without interruption. |
| Firmware Installation Required | The controller is using boot firmware (that is revision1.xxx) and requires a firmware upgrade.Upgrade controller firmware. |
| SD Card Locked | An SD card that is locked is installed. |
Fault Messages
If the controller displays a fault, these messages can be indicated on the status display.| Fault Messages |
| Message | Interpretation |
| Major Fault TXX:CXX message | A major fault of Type XX and Code XX has been detected. |
| I/O Fault Local:X #XXXX message | An I/O fault has occurred on a module in the local chassis. The slot number and fault code are indicated along with a brief description.Take corrective action specific to the type of fault indicated. |
| I/O Fault ModuleName #XXXX message | An I/O fault has occurred on a module in a remote chassis. The name of the faulted module is indicated with the fault code and brief description of the fault.Take corrective action specific to the type of fault indicated. |
| I/O Fault ModuleParent:X #XXXX message | An I/O fault has occurred on a module in a remote chassis. The parent name of the module is indicated because no module name is configured in the I/O Configuration tree of Logix Designer application. In addition, the fault code is indicated with a brief description of the fault.Take corrective action specific to the type of fault indicated. |
| X I/O Faults | I/O faults are present and X = the number of I/O faults present.If there are multiple I/O faults, the controller indicates that the first fault reported. As each I/O fault is resolved, the number of faults indicated decreases and the I/O Fault message indicates the next fault reported.Take corrective action specific to the type of fault indicated. |
Major Fault Messages
The Major Fault TXX:CXX message on the controller status display indicates major faults. The table lists fault types, codes, and the associated messages as they are shown on the status display.| Major Fault Messages |
| Type | Code | Message |
| 1 | 1 | Run Mode Powerup |
| 1 | 60 | Nonrecoverable |
| 1 | 61 | Nonrecoverable – Diagnostics Saved on CF Card |
| 1 | 62 | Nonrecoverable – Diagnostics and Program Saved on SD card |
| 3 | 16 | I/O Connection Failure |
| 3 | 20 | Chassis Failure |
| 3 | 21 |
| 3 | 23 | Connection Failure |
| 4 | 16 | Unknown Instruction |
| 4 | 20 | Invalid Array Subscript |
| 4 | 21 | Control Structure LEN or POS<0 |
| 4 | 31 | Invalid JSR Parameter |
| 4 | 34 | Timer Failure |
| 4 | 42 | Invalid JMP Target |
| 4 | 82 | SFC Jump Back Failure |
| 4 | 83 | Value Out of Range |
| 4 | 84 | Stack Overflow |
| 4 | 89 | Invalid Target Step |
| 4 | 90 | Invalid Instruction |
| 4 | 91 | Invalid Context |
| 4 | 92 | Invalid Action |
| 4 | 990 | User-defined |
| 4 | 991 |
| 4 | 992 |
| 4 | 993 |
| 4 | 994 |
| 4 | 995 |
| 4 | 996 |
| 4 | 997 |
| 4 | 998 |
| 4 | 999 |
| 6 | 1 | Task Watchdog Expired |
| 7 | 40 | Save Failure |
| 7 | 41 | Bad Restore Type |
| 7 | 42 | Bad Restore Revision |
| 7 | 43 | Bad Restore Checksum |
| 7 | 44 | Failed to Restore Processor Memory |
| 8 | 1 | Keyswitch Change Ignored |
| 11 | 1 | Positive Overtravel Limit Exceeded |
| 11 | 2 | Negative Overtravel Limit Exceeded |
| 11 | 3 | Position Error Tolerance Exceeded |
| 11 | 4 | Encoder Channel Connection Fault |
| 11 | 5 | Encoder Noise Event Detected |
| 11 | 6 | Sercos Drive Fault |
| 11 | 7 | Synchronous Connection Fault |
| 11 | 8 | Servo Module Fault |
| 11 | 9 | Asynchronous Connection Fault |
| 11 | 10 | Motor Fault |
| 11 | 11 | Motor Thermal Fault |
| 11 | 12 | Drive Thermal Fault |
| 11 | 13 | Sercos Communications Fault |
| 11 | 14 | Inactive Drive Enable Input Detected |
| 11 | 15 | Drive Phase Loss Detected |
| 11 | 16 | Drive Guard Fault |
| 11 | 32 | Motion Task Overlap Fault |
| 11 | 33 | CST Reference Loss Detected |
| 12 | 32 | Disqualified Secondary Controller Cycle Power |
| 12 | 33 | Unpartnered Controller Identified in New Primary Chassis |
| 12 | 34 | Keyswitch Positions of Primary and Secondary Controllers Mismatched |
| 14 | 1 | Safety Task Watchdog Expired |
| 14 | 2 | Error In Routine of Safety Task |
| 14 | 3 | Safety Partner Missing |
| 14 | 4 | Safety Partner Unavailable |
| 14 | 5 | Safety Partner Hardware Incompatible |
| 14 | 6 | Safety Partner Firmware Incompatible |
| 14 | 7 | Safety Task Inoperable |
| 14 | 8 | Coordinated System Time (CST) Not Found |
| 14 | 9 | Safety Partner Nonrecoverable Controller Fault |
| 18 | 1 | CIP Motion Initialization Fault |
| 18 | 2 | CIP Motion Initialization Fault Mfg |
| 18 | 3 | CIP Motion Axis Fault |
| 18 | 4 | CIP Motion Axis Fault Mfg |
| 18 | 5 | CIP Motion Fault |
| 18 | 6 | CIP Module Fault |
| 18 | 7 | Motion Group Fault |
| 18 | 8 | CIP Motion Configuration Fault |
| 18 | 9 | CIP Motion APR Fault |
| 18 | 10 | CIP Motion APR Fault Mfg |
| 18 | 128 | CIP Motion Guard Fault |
I/O Fault Codes
The controller indicates I/O faults on the status display in one of these formats:• I/O Fault Local: X #XXXX message• I/O Fault ModuleName #XXXX message• I/O Fault ModuleParent: X #XXXX messageThe first part of the format is used to indicate the location of the module with a fault. How the location is indicated depends on your I/O configuration and the properties of the module that are specified in Logix Designer application.The latter part of the format, #XXXX message, can be used to diagnose the type of I/O fault and potential corrective actions.| I/O Fault Codes |
| Code | Message |
| #0001 | Connection Failure |
| #0002 | Insufficient Resource |
| #0003 | Invalid Value |
| #0004 | IOI Syntax |
| #0005 | Destination Unknown |
| #0006 | Partial Data Transferred |
| #0007 | Connection Lost |
| #0008 | Service Unsupported |
| #0009 | Invalid Attribute Value |
| #000A | Attribute List Error |
| #000B | State Already Exists |
| #000C | Object Mode Conflict |
| #000D | Object Already Exists |
| #000E | Attribute Not Settable |
| #000F | Permission Denied |
| #0010 | Device State Conflict |
| #0011 | Reply Too Large |
| #0012 | Fragment Primitive |
| #0013 | Insufficient Command Data |
| #0014 | Attribute Not Supported |
| #0015 | Data Too Large |
| #0100 | Connection In Use |
| #0103 | Transport Not Supported |
| #0106 | Ownership Conflict |
| #0107 | Connection Not Found |
| #0108 | Invalid Connection Type |
| #0109 | Invalid Connection Size |
| #0110 | Module Not Configured |
| #0111 | RPI Out of Range |
| #0113 | Out of Connections |
| #0114 | Wrong Module |
| #0115 | Wrong Device Type |
| #0116 | Wrong Revision |
| #0117 | Invalid Connection Point |
| #0118 | Invalid Configuration Format |
| #0119 | Module Not Owned |
| #011A | Out of Connection Resources |
| #0203 | Connection Timeout |
| #0204 | Unconnected Message Timeout |
| #0205 | Invalid Parameter |
| #0206 | Message Too Large |
| #0301 | No Buffer Memory |
| #0302 | Bandwidth Not Available |
| #0303 | No Bridge Available |
| #0304 | ControlNet Schedule Error |
| #0305 | Signature Mismatch |
| #0306 | CCM Not Available |
| #0311 | Invalid Port |
| #0312 | Invalid Link Address |
| #0315 | Invalid Segment Type |
| #0317 | Connection Not Scheduled |
| #0318 | Invalid Link Address |
| #0319 | No Secondary Resources Available |
| #031E | No Available Resources |
| #031F | No Available Resources |
| #0800 | Network Link Offline |
| #0801 | Incompatible Multicast RPI |
| #0814 | Data Type Mismatch |
| #FD01 | Data Type Mismatch |
| #FD02 | No Error Code |
| #FD03 | Missing Required Connection |
| #FD04 | No CST Master |
| #FD05 | Axis or GRP Not Assigned |
| #FD06 | Sercos Transition Fault |
| #FD07 | Sercos Init Ring Fault |
| #FD08 | Sercos Comm Fault |
| #FD09 | Sercos Init Node Fault |
| #FD0A | Axis Attribute Reject |
| #FD1F | Safety I/O |
| #FD20 | No Safety Task |
| #FE01 | Invalid Connection Type |
| #FE02 | Invalid Update Rate |
| #FE03 | Invalid Input Connection |
| #FE04 | Invalid Input Data Pointer |
| #FE05 | Invalid Input Data Size |
| #FE06 | Invalid Input Force Pointer |
| #FE07 | Invalid Output Connection |
| #FE08 | Invalid Output Data Pointer |
| #FE09 | Invalid Output Data Size |
| #FE0A | Invalid Output Force Pointer |
| #FE0B | Invalid Symbol String |
| #FE0C | Invalid Scheduled Personal Computer Instance |
| #FE0D | Invalid Symbol Instance |
| #FE0E | Module Firmware Updating |
| #FE0F | Invalid Firmware File Revision |
| #FE10 | Firmware File Not Found |
| #FE11 | Firmware File Invalid |
| #FE12 | Automatic Firmware Update Failed |
| #FE13 | Update Failed - Active Connection |
| #FE14 | Searching Firmware File |
| #FE22 | Invalid Connection Type |
| #FE23 | Invalid Unicast Allowed |
| #FF00 | No Connection Instance |
| #FF01 | Path Too Long |
| #FF04 | Invalid State |
| #FF08 | Invalid Path |
| #FF0B | Invalid Config |
| #FF0E | No Connection Allowed |
PLC Controller - Mark and Trace Local PLC Adaptations
| Equipment Status | Program Step |
Personnel Requirements.Only authorised and skilled personnel are allowed to make changes in the PLC program.Changing the PLC program can affect the machine in unexpected ways.
All local adaptations must, if possible, be made inside the program LocalAdaptations. Changes and adaptations that are not inside the LocalAdaptations program must be marked according to below.Note: For further information, see the Electrical Manual (EM).- Mark the Rung, where the adaptation is, with the tag
LA_LocalAdaptation to do a local adaptation in the PLC program. This tag is always on.In the example below, a main shaft position has been adjusted and marked with the LA_LocalAdaptation tag. 
- Rung
- To trace all local adaptations, make a cross reference on the
LA_LocalAdaptation tag. A list over all positions where the tag is used in the program is displayed.The tag is created at the end of MainProgram /MP_SystemController routine. Do not make changes in this rung.The tag is also used to mark the local alarms. See Section Local Alarms below. 
- MainProgram /MP_SystemController routine
- It is possible to make connections to and from the PLC. There are four inputs and four outputs that are reserved for local adaptations or customers local changes.The Inputs are connected to the A01X0206 terminal block (see the table below). The external connection must be connected to the A01X0206 terminal. The Inputs are not potentially separated from the rest of the machine.
| Connection | Tag Name |
| A01X0206:50 | MC_A01X0206_50_ReservedForCust |
| A01X0206:51 | MC_A01X0206_51_ReservedForCust |
| A01X0206:52 | MC_A01X0206_52_ReservedForCust |
| A01X0206:53 | MC_A01X0206_53_ReservedForCust |
The outputs are connected to four relays (see the table below). The external connection must be connected directly on the relays.| Connection | Tag Name |
| A01K0108 | MC_A01K0108_ReservedForCust |
| A01K0109 | MC_A01K0109_ReservedForCust |
| A01K0110 | MC_A01K0110_ReservedForCust |
| A01K0111 | MC_A01K0111_ReservedForCust |
Note: Always save the programs to the SD cards when you have made any changes. See 7.2.2-11.1 PLC Controller - Save the Online.
It is possible to add buttons with local adaptations in the setting and Information Electrical Cabinet window.- Access the Buttons:In the Main Menu window, press Setting and Information Electrical Cabinet.

- Setting and Information Electrical Cabinet
- Buttons
- Make the buttons visible in the setting and Information Electrical Cabinet window:In Controller Tags, change the Value to 1 for the Tag Name in the table.
| Button | Tag Name | Value |
A | MC_HMI_Var_Control.26 | 1 |
B | MC_HMI_Var_Control.27 | 1 |
C | MC_HMI_Var_Control.28 | 1 |
D | MC_HMI_Var_Control.29 | 1 |

- Value
- Tag Name
- In Controller Tags, use the following Tag Name for appropriate actions in the PLCLogic program.
| Tag Name |
| HMI_MC_Var_Control.26 |
| HMI_MC_Var_Control.27 |
| HMI_MC_Var_Control.28 |
| HMI_MC_Var_Control.29 |

- Tag Name
- When finished with the local adaptations, in
MainTask / MainProgram, open the MP_SystemController and write the Date when the local adaptation was implemented. 
- Date
Local Alarms
It is possible to set four customer alarms on each side. The alarms will be shown in the Electrical Cabinet Alarm window.
- Electrical Cabinet Alarm window
The number in the table below refers to the number in the tag name.| Tag Name | Program Action |
| SUP1_110720910_CustAlarm1Active | Side 1 Alarm level 5* (Quick stop) |
| SUP2_110720920_CustAlarm2Active | Side 2 Alarm level 5* (Quick stop) |
| SUP1_110720931_CustAlarm3Active | Side 1 Alarm level 28** (Stop paper feed side 1) |
| SUP2_110720932_CustAlarm4Active | Side 2 Alarm level 29*** (Stop paper feed side 2) |
| SUP1_110720951_CustAlarm5Active | Side 1 Alarm level 50**** (Indication) |
| SUP2_110720952_CustAlarm6Active | Side 2 Alarm level 50**** (Indication) |
| SUP1_110720971_CustAlarm7Active | Side 1 Alarm level 28** (Stop paperfeed side 1) |
| SUP2_110720972_CustAlarm8Active | Side 2 Alarm level 29*** (Stop paperfeed side 2) |
| SUP1_110720981_CustAlarm9Active | Side 1 Alarm level 51 ***** (Automatic restart side 1) |
| SUP2_110720982_CustAlarm10Active | Side 2 Alarm level 52 ****** (Automatic restart side 2) |
| *Alarm Level 5: Motors stop immediately and machine steps to position 3.To be used for alarms, stopping production on both sides, logged in PLMS. |
|
| **Alarm Level 28: Production stop on side 1To be used for alarms, stopping production on side 1 only, logged in PLMS. |
|
| ***Alarm Level 29: Production stop on side 2To be used for alarms, stopping production on side 2 only, logged in PLMS. |
|
| ****Alarm Level 50: Blue alarm to get the operators attentionTo be used for alarms, NOT stopping production, logged in PLMS. |
|
| *****Alarm level 51: Blue alarm to get the operators attention.To be used for alarms, automatic restart on side 1, logged in PLMS. |
|
| ******Alarm level 52: Blue alarm to get the operators attention.To be used for alarms, automatic restart on side 2, logged in PLMS. |
Note: Valid for 1800 machines Local Alarms 9 and 10 are only valid for the IC variant.Note: Valid for 1800 machines On XH machines, alarm level 50 is alarm level 30.New String tags in the PLC-Logic for all Local alarms can be edited in the local language. This string can then be seen as text on the TPOP-screen as the alarm help text.The code for the alarms is located in the end of SUPPLY/SUP_ Alarm_Electrical routine.The example shows the Local Alarm 1. The structure and function are the same for all six alarms.To activate the alarms- change the
XIO LA_LocalAdaptation to Change from XIO to XIC. - add the code for the specific alarm in the Local area code field.

- SUPPLY/SUP_ Alarm_Electrical routine
- Change from XIO to XIC
- Local area code
PLC Program - Download to the PLC Controller
| Equipment Status | Program Step |
| Special Equipment | Computer with RSLogix installed |
Note: If the TPOP is restarted when the distribution equipment is switched off, the NRG logger may not work. It can also happen if the distribution equipment is restarted, lost power or in some way lost communication with the TPOP. If the NRG logger is not working, make sure the distribution equipment is switched on, and restart the TPOP.Personnel Requirements.Only authorised and skilled personnel are allowed to download the PLC program to the PLC Controller.Changing the PLC program can affect the machine in unexpected ways.
All the values and settings in the PLC Controller will be replaced with the ones from the downloaded program. To save the current values and settings save the values to the ControlFlash card before downloading the new program. See PLC Controller to SD Card - Save to File on page PLC Controller to SD Card - Save to File.- Copy the PLC program file to the computer.
- The PLC programs are distributed either as *.ACD files or *.L5K files.
- If it is an *.ACD file, double click the file and RSLogix will start with the correct project opened.
- If it is a *.L5K file, start RSLogix and open the file from the File menu in RSLogix.
- Use the Communication menu in RSLogix and select Go online.
- If the program:
- matches the program in the PLC Controller, an online connection is established without any further messages. A download is not necessary.
- does not match the program in the PLC Controller, the Connected To Go Online window will appear.
- Click Download.

- Go online
- Connected To Go Online window
- Download
- Click Download.

- Download
- When the download is complete, click Yes. The PLC Controller will change back to Remote Run and start executing the program.

- Yes
- Make the Initial Machine Setting.
PLC Program - Upload from the PLC Controller
| Equipment Status | Program Step |
| Special Equipment | Computer with RSLogix installed Keyboard with USB connector |
Upload in an Earlier Project
- Perform steps PLC Program - Download to the PLC Controller - PLC Program - Download to the PLC Controller in PLC Program - Download to the PLC Controller.
- Click Upload and then
Upload in the new window.- The upload takes several minutes. When the dialogue box disappears the upload is complete.

- Upload
Upload to a New Project Without a Previous Project
- Start RSLogix.
- From the
Communication menu select Who Active. 
- Who Active
- Expand the Path tree as shown in the illustration below.
- Select the PLC Controller that is to be connected to (in the example in the illustration below the Logic CPU is selected).
- Click Go Online.

- Path tree
- Go Online
- Click Select File.

- Select File
- Select a location and a name on the program and then click the Select.
- Click Yes. The upload starts.

- Select
- Yes
- The upload is completed when the time bar disappears. Select Save from the
File menu. - If the tag values should be included, click Yes.
- If the tag values should not be included, click No.
- The saving is completed when the time bar disappears.

- Save
- Yes
- No
PLC Controller, SERCOS, DeviceNet, Ethernet Cards and Servo Drive - Load Firmware (FW)
| Equipment Status | Program Step |
| Special Equipment | Computer with RSLogix installed Network cable CD: Machine Software |
Personnel Requirements.Only authorised and skilled personnel are allowed to load firmware.Changing the PLC program can affect the machine in unexpected ways.
If the FW-update is interrupted by, for example, a power loss on the machine, or if the communication fails between the device and the PC, the PLC-Device will be corrupt and must be sent to repair.New PLC Controller modules are delivered without any Firmware and have to be installed before any machine programs can be downloaded.If the firmware is changed on the Cam module or on the Conveyor servo drive perform the following steps before continuing this procedure.- Step up the machine to Air on.
- Individually inch the axis to zero degrees. (Individual axis is described in Operation Manual, section 1.6 Inching).
- Step down the machine to step zero.
- Install Control Flash from the Machine Software CD, see the Read me file on the CD for instructions.
- Set both the PLC Controllers in Program Mode.
- Make sure that the network card in the computer and RSLinx are configured. See Preparation for PLC Communication - Assign Computer IP Address and Preparation for PLC Communication - Configure RSLinx.
- Connect the network cable between the computer and the network switch A01K0003 and make sure that the network cables between the switch and the Ethernet modules are connected.
- From the
Start menu, select: 
- Programs
- Flash Programming Tools
- Control Flash
- The following procedure can be used to load firmware to:
- Logic CPU A01K0025
- Motion CPU A01K0027
- SERCOS module A01K0032
- SERCOS module A01K0033
- Ethernet card A01K0029
- DeviceNet card A01K0030
- DeviceNet card A01K0031
- Ethernet card A01K0011
- Servo Drive Kinetix 6000
- See the tables below for correct product and revision number.
| Load Firmware in: | Product No. | Part No. |
| Logic CPU A01K0025 (Pos 0) | 1756-L61 | 90459-6558 |
| Motion CPU A01K0027 (Pos 1) | 1756-L61 | 90459-6558 |
| SERCOS module A01K0032 (Pos 5) | 1756-M16SE | 90459-2481 |
| SERCOS module A01K0033 (Pos 6) | 1756-M16SE | 90459-2481 |
| Ethernet card A01K0029 (Pos 2) | 1756-ENBT | 90459-2477 |
| DeviceNet card A01K0030 (Pos 3) | 1756-DNB | 90459-2479 |
| DeviceNet cardA01K0031(Pos 4) | 1756-DNB | 90459-2479 |
| Ethernet card A01K0011(Pos 0) | 1756-ENBT | 90459-2477 |
Load Firmware in Servo Drive Kinetix:
| Node no. | Product No. | Loop |
| 10 | F11 2094-BC01-M01-S (9A) | 1 |
| 11 | F12 2094-BM01-S/A (9A) | 1 |
| 12 | F21 2094-BM01-S/A (9A) | 1 |
| 13 | F22 2094-BM01-S/A (9A) | 1 |
| | |
| 20 | Conv 2094-BC02-M02-S (15A) | 2 |
| 21 | FiLif1 2094-BM01-S/A (9A) | 2 |
| 22 | BSLi1 2094-BM01-S/A (9A) | 2 |
| 23 | BSHo1 2094-BM01-S/A (9A) | 2 |
| 24 | Spare | 2 |
| | |
| 30 | Disch 2094-BC02-M02-S (15A) | 2 |
| 31 | FiLif2 2094-BM01-S/A (9A) | 2 |
| 32 | BSLif2 2094-BM01-S/A (9A) | 2 |
| 33 | BSHo2 2094-BM01-S/A (9A) | 2 |
| 34 | Outfeed side pusher | 2 |
| | |
| 40 | RecPl 2094-BC02-M02-S (15A) | 1 |
| 41 | Man1 2094-BM02-S/A (15A) | 1 |
| 42 | LfuT1 2094-BM02-S/A (15A) | 1 |
| 43 | PapF1 2094-BM01-S/A (9A) | 1 |
| 44 | Cap11 2094-BM01-S/A (9A) | 1 |
| 45 | Cap12 2094-BM01-S/A (9A) | 1 |
| | |
| 50 | Man2 2094-BC02-M02-S (15A) | 1 |
| 51 | LfuT2 2094-BM02-S/A (15A) | 1 |
| 52 | PapF2 2094-BM01-S/A (9A) | 1 |
| 53 | Cap21 2094-BM01-S/A (9A) | 1 |
| 54 | Cap22 2094-BM01-S/A (9A) | 1 |
| 55 | Spare | 1 |
| | |
| 60 | Mag1 2094-BC02-M02-S (15A) | 2 |
| 61 | Mag2 2094-BM02-S/A (15A) | 2 |
| 62 | Str1 2094-BM01-S/A (9A) | 2 |
| 63 | Str2 2094-BM01-S/A (9A) | 2 |
| 64 | CaLif1 2094-BM01-S/A (9A) | 2 |
| 65 | CaLif2 2094-BM01-S/A (9A) | 2 |
- In the Control Flash program window click Next.

- Control Flash program window
- Next
- Select the product number for the target device and click Next.

- Next
- Select the device that should be updated (expand the path by clicking on the +). Then click Ok.

- Ok
- The program suggests a suitable firmware version. To select another version, click Show all and select another one. Click Next.

- Next
- Show all
- Click Finish and then Yes.


- Finish
- Yes
- A new revision of firmware is being loaded, the module will automatically reboot.
- The upgrade is finished. Click Ok.

- Ok
- If the firmware is changed on any absolute axis, for example an axis that cannot search for its home position, but have to be manually homed, (Cam module, Mandrel wheel and Conveyor), the axis position is lost and has to be redefined. In order to redefine the axis refer to the following chapters in Maintenance Manual.
PLC Controller to SD Card - Save to File
| Equipment Status | Program Step step zero |
- Change the recipe in the TPOP from, for example, recipe 1 to recipe 2 on side 1, see 6.2 Change Product in OM. (Chapter 6.3 Change Product on XH machines.)
- Change the recipe in the TPOP from, for example, recipe 1 to recipe 2 on side 2, see 6.2 Change Product in OM. (Chapter 6.3 Change Product on XH machines.)
- Change back to the preferred recipe on side 1 and side 2.
This instruction describes the procedure for S1. The procedure for S2 is similar.Note: It is only possible to Save to File when both sides of the machine are in step zero.- Press
Main.
- Select Save to file and change
NO to YES. - Press Exit.
- Press
Save. 
- Save to file
- Exit
When the Save to File is completed, an Acknowledge button opens in the lower part of the screen.If an Error button opens, instead of the Acknowledge button, the function has failed.- Check if the SD card is correctly inserted in the PLC Controller.
- Redo the Save to File.
- Press the Acknowledge button and the store function is completed.Note: Problems with SD cards do not affect the performance of the machine. The cards are only used as a backup media for the PLC programs and machine settings.

- Acknowledge button
- Error button
SD Card to PLC Controller - Load from File
| Equipment Status | Program Step step zero |
This instruction shows the procedure for S1. The procedure for S2 is the same as for S1.Note: It is only possible to Load from File when both sides of the machine are in step zero.- Press
Main.
- Select Load from file and change
NO to YES. - Press Exit.
- Press
Save. 
- Load from file
- Exit
When the Load from File is completed, an Acknowledge button appears in the lower part of the screen.If an Error button appears, instead of the Acknowledge button, the function has failed.- Check if the SD card is correctly inserted in the PLC Controller.
- Redo the Load from File.
- Press the Acknowledge button and the store function is completed.Note: Problems with SD cards do not affect the performance of the machine. The cards are only used as a backup media for the PLC programs and machine settings.

- Acknowledge button
- Error button
- Change the recipe in the TPOP from for example recipe 1 to recipe 2 on side 1, see 6.2 Change Product in OM. (Chapter 6.3 Change Product on XH machines.)
- Change the recipe in the TPOP from example recipe 1 to recipe 2 on side 2, see 6.2 Change Product in OM. (Chapter 6.3 Change Product on XH machines.)
- Change back to the preferred recipe on side 1 and side 2.
Distributed I/O
Note: Series mismatch.When replacing a component that contains firmware, it is important that the components have the same series as the old ones.Note: Revision mismatch.It might be possible to use a component with a new revision, but it is recommended to use the same revision as the old one.The series and revision is printed on the component.Functional Description
The communication and connections between different devices in the machine is provided through a DeviceNet network. The higher-level devices, such as controllers are connected to more simple devices such as sensors, actuators, and other parts.In addition to reading the states of on/off sensors and operating motor starters, the DeviceNet network reports temperatures and the load current in the motor starter, changes the deceleration rates of drives, adjusts the sensitivities of sensors, and more.DeviceNet
In the TT/3 machine there are three DeviceNet networks, DeviceNet 1, DeviceNet 2, and DeviceNet 3. To see which DeviceNet node that belongs to which network, see the table that starts on page Reference.A Control Logix PLC and three DeviceNet scanners 1756-DNB are installed in the electrical cabinet.The DeviceNet scanners 1756-DNB is a communication interface between the Control Logix PLC and the DeviceNet network. The DeviceNet scanner scans the network and reads and writes data from and to the network nodes.
* Optional equipment Gas Dosing System** Variant
XH with
IC*** Variant
AD,
ADY,
ASD,
ASCM, and
AW**** Variant USA/Canada
- DeviceNet 1
- DeviceNet 2
- DeviceNet 3
- Control Logix PLC
- DeviceNet scanners 1756-DNB
- Electrical Cabinet
- ASU
- LFU
- CAU
- TTCU
- Carton Section
- Filling Section
- Package Section
The logic CPU communicates with the Point I/O modules and the frequency converters through the three DeviceNet scanners A01K0030, A01K0031, and A01K0039. The DeviceNet scanners are located in place 3, 4, and 12 of the CPU rack in the electrical cabinet. From each scanner there are two trunk lines, one to the frequency converter in the electrical cabinet and one for the Point I/O and the frequency converter on the filling machine. A termination resistor must be connected between the blue and white connection on the end of each trunk line from the scanners.The trunk line is the cable path between terminators that serves as the backbone of the DeviceNet network. The trunk line connects to taps or directly to devices. A tap is screw terminals that connect a drop line to the trunk line.The modules that are connected to each scanner must have an individual address, a node number. The setting of the node numbers on the Point I/O (9 pieces of P I/O) modules is done on the Thumb wheel on the first ADN module. Setting of address number and baud rate, see section DeviceNet Scanner Module - Set Address Number and Baud Rate on page DeviceNet Scanner Module - Set Address Number and Baud Rate.
- Thumb wheel
Note: It is important that the modules are connected to the proper scanner. See the table below. The reciprocal order is not important since the modules are connected in parallel, but it is important that the last module in each loop have a termination resistor connected between the blue and white connection (121 Ohm, 1%, ¼ W).| Node | Trunk line | Func No | Name | Switch Position/ Address Adjustment | Termination Resistor |
| 00 | Electrical Cabinet | A01K0030 | DNB Scanner module1Place 3 in CPU Rack | Addr 00 Baud 500 | |
| 01 | Electrical Cabinet | G65T1004 | F/C Outfeed 1 |  | |
| 02 | Electrical Cabinet | G65T2004 | F/C Outfeed 2 |  | |
| 03 | Electrical Cabinet | A30T1005 | F/C Gran Screw 1 |  | |
| 04 | Electrical Cabinet | A30T2005 | F/C Gran Screw 2 |  | |
| 56 | Electrical Cabinet | T12K0001 | TMCC2 | Address in TMCC2 program | 121 ohm, ¼ W |
| 09 | Machine | A02K0400 | P I/O Filling Section A | 09 | |
| 10 | Machine | A02K0440 | P I/O Filling Section B | 10 | |
| 08** | Machine | A02K0485 | P I/O Filling Section C USA | 08 | |
| 11 | Machine | V68T1213 | F/C Hepa Fan 1 |  | |
| 12 | Machine | V68T2213 | F/C Hepa Fan 2 |  | |
| 13 | Machine | V68T1209 | F/C Tank Vent L1 |  | |
| 14 | Machine | V68T2209 | F/C Tank Vent L2 |  | |
| 15 | Machine | V51T1032 | F/C UV Fan L1 |  | |
| 16 | Machine | V51T2032 | F/C UV Fan L2 |  | |
| 17 | Machine | V51T1033 | F/C Peroxide reducer S1 |  | |
| 18 | Machine | V51T2033 | F/C Peroxide reducer S2 |  | |
| 20 | Machine | A02K1300 | P I/O Pack Sect L1 | 20 | |
| 21 | Machine | A02K2300 | P I/O Pack Sect L2 | 21 | 121 ohm, ¼ W* |
| 40* | Machine | A02K0985 | P I/O Gas Dosing System | 40 | 121 ohm, ¼ W* |
| *Optional equipment Gas Dosing. If Gas Dosing System is installed the resistance must be moved from node 21 to node 40.**Variant USA/Canada |
| Node | Trunk line | Func No | Name | Switch Position/ Address Adjustment | Termination Resistor |
| 00 | Electrical Cabinet | A01K0031 | DNB Scanner module 2Place 4 in CPU Rack | Addr 00Baud 500 | |
| 01 | Electrical Cabinet | T12T1004 | F/C Slack 1 CS |  | |
| 02 | Electrical Cabinet | T12T2004 | F/C Slack 2 CS |  | 121 ohm, ¼ W** |
| 03 | Electrical Cabinet | T21T1021 | F/C Sleeve 1 |  | |
| 04 | Electrical Cabinet | T21T2021 | F/C Sleeve 2 |  | |
| 05*** | Electrical Cabinet | G31T1022 | F/C CAU Cap Sorter S1 |  | |
| 06*** | Electrical Cabinet | G31T2022 | F/C CAU Cap Sorter S2 |  | 121 ohm, ¼ W |
| 07**** | Electrical Cabinet | V51T0031 | F/C HEPA Fan LFU |  | |
| 10 | Machine | A02K0001 | P I/O ASU | 10 | |
| 11 | Machine | T10T1215 | F/C Slack 1 ASU |  | |
| 12 | Machine | T10T2215 | F/C Slack 2 ASU |  | 121 ohm, ¼ W** |
| 20 | Machine | A02K0140 | P I/O Cart Sect L1 | 20 | |
| 35 | Machine | A01A1010 | TPOP Gateway S1 | 35 | |
| 21 | Machine | A02K0170 | P I/O Cart Sect L2 | 21 | |
| 36 | Machine | A01A2010 | TPOP Gateway S2 | 36 | |
| 22 | Machine | A02K0100 | P I/O Cart Sect Valves | 22 | |
| 30 | Machine | A02K1200 | P I/O LFU L1 | 30 | |
| 31 | Machine | A02K2200 | P I/O LFU L2 | 31 | |
| 50** | Machine | A02K0900 | P I/O CAU | 50 | |
| ***Variant XH with IC. If the machine is equipped with IC the resistance must be moved from node 02 to node 06.****Variant AD, ADY, SD, ASCM, and Water |
| Node | Trunk line | Func No | Name | Switch Position/ Address Adjustment | Termination Resistor |
| 00 | Electrical Cabinet | A01K0039 | DNB Scanner module 3Place 12 in CPU Rack | Addr 00Baud 500 | |
| 01 | TTCU Cabinet | V80T0001 | F/C Pressure pump TTCU |  | |
| 02 | Electrical Cabinet | V67T0003 | F/C Return pump M/C TTCU |  | 121 ohm, ¼ W** |
| 10 | TTCU Cabinet | V80T6400 | P I/O TTCU | 10 | |
| 15 | TTCU Cabinet | V80X1011 | FESTO-node TTCU |  | 121 ohm plug |
I/O Modules
DeviceNet nodes are placed on the machine modules such as Point I/O adapters (1734-ADN) and frequency converters (PowerFlex40), see the illustration below.The Point I/O node signals are wired to the I/O modules.I/O modules come in a wide range of different types. Digital, analogue, and thermocouple I/O modules are used in the TT/3 machine.Adapter (1734-ADN)
The adapter (1734-ADN) has double functionality. On the backplane it acts as an I/O scanner to the I/O modules and collects the I/O data. On the main DeviceNet it acts as an adapter, and data is collected by the 1756-DNB module.There are different ways of communicating with the I/O modules. This means that there are different delay times compared to a non distributed I/O solution.
A = 1734-ADNB = I/O ModulesC = DeviceNetD = AdapterE = Scanner

Interlocking side pieces

- 1734-ADN DeviceNet adapter module
- DeviceNet connector
- Node address terminal
- Status indicators - Adapter DeviceNet and pointbus
- DIN Rail locking screw (orange)
- System power and field powers indicators
- RTB Removal handle
- Removable terminal block (RTB)
PowerFlex40 (PF40)
PowerFlex40 (PF40) is a frequency drive on the DeviceNet. All of the drive parameters are downloaded from the DeviceNet scanner 1756-DNB when the drive is powered on.Status Indicators
On each DeviceNet node there are LEDs; 1743-ADN indicators (1), PowerFlex40 indicators (2), and LED on I/O modules (3), indicating the status of the module and the network communication. It is possible to see on the LED if something is wrong with the network devices which simplifies maintenance and troubleshooting. |
| Adapter 1734-ADN | Frequency drive PowerFlex40 | I/O module |
| | |
| | Solid yellow = ON |
| | Dark = OFF |
11734-ADN indicators2PowerFlex40 indicators3LED on I/O modulesConfiguration Tools
By using the software RSLogix5000 and RSNetworx for DeviceNet the network and the PLC system can be configured.Power Supply and Cable Coding
Each of the networks is connected to a separate 24 VDC power supply and has a terminating resistor (TR) (121 ohm), attached to the ends of the trunk line.The Drop line is the cable path that connects taps to nodes on the network.The Device box is a junction box that allows two, four or eight drop lines to be connected to the trunk line via terminal strip connections.The network cable is colour coded to avoid wiring faults: | +24 VDC (V+) | Red |
| CAN -H | White |
| Drain | Shield or Bare |
| CAN -L | Blue |
| +0 VDC (V-) | Black |

* Optional equipment Gas Dosing System** Variant
XH with
IC*** Variant
AD,
ADY,
SD,
ASCM, and Water
- Drop line
- Device box
- Electrical Cabinet
- ASU
- LFU
- CAU
- TTCU
- Carton Section
- Filling Section
- Package Section
DeviceNet Scanner Module - Set Address Number and Baud Rate
| Equipment Status | Program Step step zero |
Personnel Requirements.Only authorised and skilled personnel are allowed to change the parameters.Changing the parameters can affect the machine in unexpected ways.
- Use the Switch for baud rate to set the baud rate to 500.
| Switch setting | Communication rate |
| 0 | 125 Kbps |
| 1 | 250 Kbps |
| 2 | 500 Kbps |
| 8 | When all three switches are set to 8, resets the 1756-DNB scanner module to factory default settings.Do not use for normal operation. |
| All other | Select the communication rate with RSNetWorx for DeviceNetsoftware. |
- Use the Switch for address setting and the Switch for address setting to set the address number to 00.

- Switch for baud rate
- Switch for address setting
- Switch for address setting
Frequency Converter - Set
| Equipment Status | Power must be turn OFF.
|
Personnel Requirements.Only authorised and skilled personnel are allowed to change the parameters.Changing the parameters can affect the machine in unexpected ways.
The setting of the node numbers on the 18 frequency converters is done with the Node number switches on the network card under the front cover.Note: For the frequency converters in the CSU, see on page .- Open the front cover of the frequency converter.
- Set the node number with the Node number switches.

- Node number switches
- The F/C switches 1-6 have a value when they are in position open (up). See next table.
| Switch No. | 1 | 2 | 3 | 4 | 5 | 6 |
| Value | 1 | 2 | 4 | 8 | 16 | 32 |
- The F/C switches 7 and 8 determine the baud rate.
- Set the switches to 500 kB/s by setting switch 7 down and switch 8 to open (up). See next table.
| Switch No. | 7 | 8 |
| Baud rate |  |  |
Note: Make sure that the J1 switch of the circuit card is in SRC position. 
- J1 switch
- SRC position
- Make sure that there is a jumper between 1 and 11 on the terminals on the right of switch J1.
Frequency Converter CSU - Set
| Equipment Status | Power must be turn OFF.
|
The frequency converters in the connection box for the cap supply unit are arranged according to the illustration:
- Frequency converter - fan, right container
- Frequency converter - conveyor, right container
- Frequency converter - fan, left container
- Frequency converter - conveyor, left container
Valid for PowerFlex40The frequency converters in the cap supply unit must be set according to the following table: | Fan | Conveyor |
| Name | Parameter | Value | Comment | Value | Comment |
| Motor NP Volts | P031 | 230 | Motor Data | 230 | Motor Data |
| Motor NP Hertz | P032 | 50 | Motor Data | 50 | Motor Data |
| Motor OL Current | P033 | 2.6 | Motor Data | 1.2 | Motor Data |
| Minimum Freq | P034 | 0 | Standard | 0 | Standard |
| Maximum Freq | P035 | 50 | Standard | 50 | Standard |
| Start Source | P036 | 1 | “3-Wire” | 2 | “2-Wire” |
| Stop Mode | P037 | 4 | Standard | 4 | Standard |
| Speed Reference | P038 | 4 | “Preset Freq” | 4 | “Preset Freq” |
| Accel Time 1 | P039 | 5 | Sec | 5 | Sec |
| Decel Time 1 | P040 | 5 | Sec | 5 | Sec |
| | | | | |
| Digital In 1 Sel | A051 | 4 | Standard | 4 | Standard |
| Digital In 2 Sel | A052 | 4 | Standard | 4 | Standard |
| Digital In 3 Sel | A053 | 5 | Standard | 5 | Standard |
| Digital In 4 Sel | A054 | 11 | Standard | 11 | Standard |
| | | | | |
| Preset Freq 0 | A070 | 15 | Freq 1 Hertz | 50 | Freq 1 Hertz |
| Preset Freq 1 | A071 | 45* | Freq 2 Hertz | 14 | Freq 2 Hertz |
| * This parameter differs depending on the installation and must be set according to Feed Unit - Set Fan Speed. |
This example shows how to change the parameter P031. All other parameters are changed accordingly.- Push ESCAPE a couple of times to set the frequency converter to initial position.
- Push SELECT to activate the Letter.
- Push the Arrow to change the Letter to P.
- Push SELECT to activate the Number.
- Push the Arrow to change the Number to 031.
- Push ENTER to activate the parameter P031.
- Push the Arrow to change the value of the parameter P031.
- Push ENTER to save the value of the parameter.
- Push ESCAPE a couple of times to set the frequency converter to initial position.

- ESCAPE
- SELECT
- Arrow
- ENTER
- Letter
- Number
Frequency Converter - Set
| Equipment Status | Power must be turn OFF.
|
The frequency converters in the connection box for the cap supply unit are arranged according to illustration:
- Frequency converter fan cap container
- Frequency converter - fan cap transport S1
- Frequency converter - conveyer belt S1
- Frequency converter - fan cap transport S2
- Frequency converter - conveyer belt S2
Valid for PowerFlex525Valid for Fan 90458-0855| Parameters | Fan Cap Transport | Conveyor Belt | Fan Cap Containers |
| Nr: | Name | Value | Comment | Value | Comment | Value | Comment |
| P031 | Motor NP Volt | 230 | Motor Data | 230 | Motor Data | 230 | Motor Data |
| P032 | Motor NP Hertz | 50 | Motor Data | 50 | Motor Data | 50 | Motor Data |
| P033 | Motor OL Current | 2,6 | Motor Data | 0.82 | Motor Data | 4,2 | Motor Data |
| P034 | Motor NP FLA | 2,6 | Motor Data | 0.82 | Motor Data | 4,2 | Motor Data |
| P035 | Motor NP Poles | 4 | Motor Data | 4 | Motor Data | 4 | Motor Data |
| P036 | Motor NP RPM | 2780 | Motor Data | 1350 | Motor Data | 2840 | Motor Data |
| P037 | Motor NP Power | 0,75 | Motor Data | 0,12 | Motor Data | 0,85 | Motor Data |
| P039 | Torque Perf Mode | 1 | Standard | 1 | Standard | 1 | Standard |
| P040 | Autotune | 0 | Standard | 0 | Standard | 0 | Standard |
| P041 | Accel Time1 | 5 | Sec | 5 | Sec | 5 | Sec |
| P042 | Decel Time 1 | 5 | Sec | 5 | Sec | 5 | Sec |
| P043 | Minimum Freq | 0 | Hertz | 0 | Hertz | 0 | Hertz |
| P044 | Maximum Freq | 50 | Hertz | 50 | Hertz | 50 | Hertz |
| P045 | Stop Mode | 4 | Ramp to Stop | 4 | Ramp to Stop | 4 | Ramp to Stop |
| P046 | Start Source 1 | 2 | DigIn TermBlk | 2 | DigIn TermBlk | 2 | DigIn TermBlk |
| P047 | Speed Reference 1 | 7 | Preset Freq 0 | 7 | Preset Freq 0 | 7 | Preset Freq 0 |
| Parameters | Fan Cap Transport | Conveyor Belt | Fan Cap Containers |
|
| t062 | DigIn TermBlk 2 | 49 | 3-wire | 48 | 2-wire | 49 | 3-wire |
| t063 | DigIn TermBlk 3 | 51 | 3-wire Rev | 50 | 2-wire Rev | 51 | 3-wire Rev |
| t065 | DigIn TermBlk 5 | 7 | Preset Freq 1 | 7 | Preset Freq 1 | 7 | Preset Freq 1 |
|
| A410 | Preset Freq 0 | 15 | Hertz | 50 | Hertz | 15 | Hertz |
| A411 | Preset Freq 1 | 45* | Hertz | 14 | Hertz | 35 | Hertz |
|
|
| * This parameter differs depending on the installation and must be set according to 4.9.2-1 Feed Unit - Set Fan Speed. |
Valid for PowerFlex525Valid for Fan 90532-0957| Parameters | Fan Cap Transport | Conveyor Belt | Fan Cap Containers |
| Nr: | Name | Value | Comment | Value | Comment | Value | Comment |
| P031 | Motor NP Volt | 230 | Motor Data | 230 | Motor Data | 230 | Motor Data |
| P032 | Motor NP Hertz | 50 | Motor Data | 50 | Motor Data | 50 | Motor Data |
| P033 | Motor OL Current | 2,6 | Motor Data | 0.82 | Motor Data | 3,65 | Motor Data |
| P034 | Motor NP FLA | 2,6 | Motor Data | 0.82 | Motor Data | 3,65 | Motor Data |
| P035 | Motor NP Poles | 4 | Motor Data | 4 | Motor Data | 4 | Motor Data |
| P036 | Motor NP RPM | 2780 | Motor Data | 1350 | Motor Data | 2840 | Motor Data |
| P037 | Motor NP Power | 0,75 | Motor Data | 0,12 | Motor Data | 0,95 | Motor Data |
| P039 | Torque Perf Mode | 1 | Standard | 1 | Standard | 1 | Standard |
| P040 | Autotune | 0 | Standard | 0 | Standard | 0 | Standard |
| P041 | Accel Time1 | 5 | Sec | 5 | Sec | 5 | Sec |
| P042 | Decel Time 1 | 5 | Sec | 5 | Sec | 5 | Sec |
| P043 | Minimum Freq | 0 | Hertz | 0 | Hertz | 0 | Hertz |
| P044 | Maximum Freq | 50 | Hertz | 50 | Hertz | 50 | Hertz |
| P045 | Stop Mode | 4 | Ramp to Stop | 4 | Ramp to Stop | 4 | Ramp to Stop |
| P046 | Start Source 1 | 2 | DigIn TermBlk | 2 | DigIn TermBlk | 2 | DigIn TermBlk |
| P047 | Speed Reference 1 | 7 | Preset Freq 0 | 7 | Preset Freq 0 | 7 | Preset Freq 0 |
| Parameters | Fan Cap Transport | Conveyor Belt | Fan Cap Containers |
|
| t062 | DigIn TermBlk 2 | 49 | 3-wire | 48 | 2-wire | 49 | 3-wire |
| t063 | DigIn TermBlk 3 | 51 | 3-wire Rev | 50 | 2-wire Rev | 51 | 3-wire Rev |
| t065 | DigIn TermBlk 5 | 7 | Preset Freq 1 | 7 | Preset Freq 1 | 7 | Preset Freq 1 |
|
| A410 | Preset Freq 0 | 15 | Hertz | 50 | Hertz | 15 | Hertz |
| A411 | Preset Freq 1 | 45* | Hertz | 14 | Hertz | 35 | Hertz |
|
|
| * This parameter differs depending on the installation and must be set according to 4.9.2-1 Feed Unit - Set Fan Speed. |
This example shows how to change the parameter P031. All other parameters are changed accordingly.- Push ESCAPE a couple of times to set the frequency converter to initial position.
- Push SELECT to activate the Letter.
- Push the Arrow to change the Letter to P.
- Push SELECT to activate the Number.
- Push the Arrow to change the Number to 031.
- Push ENTER to activate the parameter P031.
- Push the Arrow to change the value of the parameter P031.
- Push ENTER to save the value of the parameter.
- Perform the same procedure from item Reference to item Reference for all parameters according to the parameter list.
- Push ESCAPE a couple of times to set the frequency converter to initial position.

- ESCAPE
- SELECT
- Arrow
- ENTER
- Letter
- Number
I/O Nodes - Set Baud Rate
| Equipment Status | Power must be turn OFF.
|
If the DeviceNet Scanner module has been in Run position with an incorrect baud rate setting, the ADN modules 24 V supply power (not the network power) must be disconnected and reconnected again to make a new automatic baud rate setting. - Disconnect the 24 V connection cable from the ADN modules and reconnect it again.
- If this does not work, switch off A01F0062 (L11 24V) and A01F0066 (Class2 24V). Wait a few seconds before switching it on again.
Frequency Converters - Change Parameter
| Equipment Status | Program Step step zero |
| Special Equipment | CD with software Network cable |
Personnel Requirements.Only authorised and skilled personnel are allowed to change the parameters.Changing the parameters can affect the machine in unexpected ways.
All parameters to the frequency converters are stored in the DeviceNet project and downloaded to the DeviceNet scanner.The DeviceNet communication card in the frequency converter is internally supplied when the power (230-400VAC) to the frequency converter goes on.All frequency converter comm cards have an individual node number for correct addressing of parameters to the frequency converters.An automatic parameter transfer, from the DeviceNet scanner, is executed when the connection to the frequency converter comm card is established (the tree LED: PORT, MOD, and NET A has a steady green light).If any parameter changes have been made manually on the buttons on the frequency converter, they will be restored to the values stored in the DeviceNet scanner when the frequency converter is supplied with power again.If a single parameter has to be changed, or if the parameters to a frequency converter in the project have been set to factory setting, follow the procedure below. Look in the table for correct parameter values.Upload the Current Parameters from the Frequency Converter to the Device Net Scanner Project on the Computer
- Open the DeviceNet file containing the frequency converter that will be changed.
- Make sure that the frequency converter has a power supply.
- Click Network and select (if necessary) the path to the DeviceNet scanner to connect to the DeviceNet network.

- Network
- Check that the frequency converter is found in the network.Note: If the frequency converter is symbolised by a grey box with a question mark install the correct EDS file before continuing. Close RSNetWorx without saving anything and install the EDS file on the computer according to .
- If the frequency converter is marked Mismatch , double click on it and click OK to update the project to make sure that the revision numbers online and offline correspond.
- If the Resolve Device Mismatch – Major Revision Migration window is shown, click Cancel to continue.

- Mismatch
- OK
- Resolve Device Mismatch – Major Revision Migration window
- Cancel
- Right-click on the Frequency converter and select Properties.
- Select the tab Parameters and click Upload to upload the parameters from the frequency converter to the computer.

- Frequency converter
- Properties
- Parameters
- Upload
- Wait for the upload to finish and then click OK.

- OK
- Click Network to go offline and click Save to save the project.

- Network
- Save
- The parameters are uploaded and saved in the project on the computer and you are connected offline from the network.
- If you want to make a permanent parameter change continue to Permanent Parameter Change.
Permanent Parameter Change
- Open the DeviceNet file containing the frequency converter that will be changed.Note: Do not connect to the DeviceNet network during this part of the procedure.
- Right-click on the Frequency converter and select Properties.
- Select the tab Parameters.Note: Check the Groups check box to get the parameters organised in folders. Then they are easier to find when doing a total parameterisation.

- Frequency converter
- Properties
- Parameters
- Groups check box
- Double click on the folder containing the parameter to be changed (in the example Basic program).
- Change the value of the parameter by typing in the Current value field, or select from the drop-down menu where it is available.
- When all parameters are changed click OK.

- Basic program
- Current value field
- OK
- Right click on the DNB scanner and select
Properties. - Select the ADR tab.
- Select the frequency converter you have made the parameter change in Frequency Converter.
- Click Load Device Config (the parameters are updated to the DNB in the project).
- Make sure Configuration Recovery is checked. (Auto-Address Recovery must be empty).
- Click OK.
- Save the project.

- DNB scanner
- ADR tab
- Frequency Converter
- Load Device Config
- Configuration Recovery
- Auto-Address Recovery
- OK
| | | DevNet 1 #1 | DevNet 1 #2 | DevNet 1 #11 | DevNet 1 #12 | DevNet 1 #13 |
| | Factory Settings | Outfeeder 1 | Outfeeder 2 | HEPA Fan 1 | HEPA Fan 2 | Tank Fan 1 |
| Parameter Version 6 | Parameters | 1 Ph, 0.5 HP | 1 Ph, 0.5 HP | 1 Ph, 0.5 HP | 1 Ph, 0.5 HP | 1 Ph, 0.5 HP | 1 Ph, 0.5 HP |
| Basic Program | | | | | | | |
| 31 | Motor NP Voltage | 230 V | 230 V | 230 V | 230 V | 230 V | 230 V |
| 32 | Motor NP Frequency | 60 Hz | 50 Hz | 50 Hz | 50 Hz | 50 Hz | 50 Hz |
| 33 | Motor OL Current | 2.3 A | 1.3 A | 1.3 A | 2.2 A | 2.2 A | 2.6 A |
| 34 | Min Frequency | 0.0 Hz | 0.0 Hz | 0.0 Hz | 0.0 Hz | 0.0 Hz | 0.0 Hz |
| 35 | Max Frequency | 60 Hz | 75 Hz | 75 Hz | 60 Hz | 60 Hz | 60 Hz |
| 36 | Start Source | Keypad | Comm Port | Comm Port | Comm Port | Comm Port | Comm Port |
| 37 | Stop Mode | Ramp CF | Ramp CF | Ramp CF | Ramp CF | Ramp CF | Ramp CF |
| 38 | Speed Reference | Drive Pot | Comm Port | Comm Port | Comm Port | Comm Port | Comm Port |
| 39 | Acceleration Time 1 | 10.0 s | 1.0 s | 1.0 s | 10.0 s | 10.0 s | 10.0 s |
| 40 | Deceleration Time 1 | 10.0 s | 8.0 s | 8.0 s | 10.0 s | 10.0 s | 10.0 s |
| | | | | | | |
| Advanced Program | | | | | | | |
| 92 | Auto Rstrt | 0 | 2 | 2 | 2 | 2 | 2 |
| 105 | Comm Loss Action | Fault | Stop | Stop | Stop | Stop | Stop |
| | | | | | | |
| DeviceNet Module | | | | | | | |
| 169 | DN Address Config. | 63 | 1 | 2 | 11 | 12 | 13 |
| 171 | DN Rate Config. | Autobaud | 500 kbps | 500 kbps | 500 kbps | 500 kbps | 500 kbps |
| 174 | Comm Fault Action | Fault | Stop | Stop | Stop | Stop | Stop |
| 175 | Idle Fault Action | Fault | Stop | Stop | Stop | Stop | Stop |
| 179 | COS Status Mask | 00000000 00000000 | 11111111 11111111 | 11111111 11111111 | 11111111 11111111 | 11111111 11111111 | 11111111 11111111 |
| | DevNet 1 #14 | DevNet 1 #15 | DevNet 1 #16 | DevNet 1 #17 | DevNet 1 #18 | DevNet 2 #1 | DevNet 2 #2 |
| | Tank Fan 2 | UV Fan 1 | UV Fan 2 | Peroxide Reducer Fan 1 | Peroxide Reducer Fan 2 | CS1 Slack | CS2 Slack |
| Parameter Version 6 | Parameters | 1 Ph, 0.5 HP | 1 Ph, 0.5 HP | 1 Ph, 0.5 HP | 1 Ph, 1 HP | 1 Ph, 1 HP | 1 Ph, 0.5 HP | 1 Ph, 0.5 HP |
| Basic Program | | | | | | | | |
| 31 | Motor NP Voltage | 230 V | 230 V | 230 V | 230 V | 230 V | 230 V | 230 V |
| 32 | Motor NP Frequency | 50 Hz | 50 Hz | 50 Hz | 50 Hz | 50 Hz | 50 Hz | 50 Hz |
| 33 | Motor OL Current | 2.6 A | 2.2 A | 2.2 A | 2.6 A | 2.6 A | 0.9 A | 0.9 A |
| 34 | Min Frequency | 0.0 Hz | 0.0 Hz | 0.0 Hz | 0.0 Hz | 0.0 Hz | 0.0 Hz | 0.0 Hz |
| 35 | Max Frequency | 60 Hz | 80 Hz | 80 Hz | 100 Hz | 100 Hz | 53 Hz | 53 Hz |
| 36 | Start Source | Comm Port | Comm Port | Comm Port | Comm Port | Comm Port | Comm Port | Comm Port |
| 37 | Stop Mode | Ramp CF | Ramp CF | Ramp CF | Ramp CF | Ramp CF | Ramp CF | Ramp CF |
| 38 | Speed Reference | Comm Port | Comm Port | Comm Port | Comm Port | Comm Port | Comm Port | Comm Port |
| 39 | Acceleration Time 1 | 10.0 s | 10.0 s | 10.0 s | 10.0 s | 10.0 s | 0.6 s | 0.6 s |
| 40 | Deceleration Time 1 | 10.0 s | 10.0 s | 10.0 s | 10.0 s | 10.0 s | 0.6 s | 0.6 s |
| | | | | | | | |
| Advanced Program | | | | | | | | |
| 92 | Auto Restart | 2 | 2 | 2 | 2 | 2 | 2 | 2 |
| 105 | Comm Loss Action | Stop | Stop | Stop | Stop | Stop | Stop | Stop |
| | | | | | | | |
| DeviceNet Module | | | | | | | | |
| 169 | DN Address Config. | 14 | 15 | 16 | 17 | 18 | 1 | 2 |
| 171 | DN Rate Config. | 500 kbps | 500 kbps | 500 kbps | 500 kbps | 500 kbps | 500 kbps | 500 kbps |
| 174 | Comm Fault Action | Stop | Stop | Stop | Stop | Stop | Stop | Stop |
| 175 | Idle Fault Action | Stop | Stop | Stop | Stop | Stop | Stop | Stop |
| 179 | COS Status Mask | 11111111 11111111 | 11111111 11111111 | 11111111 11111111 | 11111111 11111111 | 11111111 11111111 | 11111111 11111111 | 11111111 11111111 |
| | DevNet 2 #3 | DevNet 2 #4 | DevNet 2 #11 | DevNet 2 #12 | DevNet 2 #5 | DevNet 2 #6 |
| | CS1 Sleeve | CS2 Sleeve | ASU1 Slack | ASU2 Slack | CAU FC1 (OAO) | CAU FC2 (OAO) |
| Parameter Version 6 | Parameters | 1 Ph, 0.5 HP | 1 Ph, 0.5 HP | 1 Ph, 0.5 HP | 1 Ph, 0.5 HP | 1 Ph, 0.5 HP | 1 Ph, 0.5 HP |
| Basic Program | | | | | | | |
| 31 | Motor NP Voltage | 230 V | 230 V | 230 V | 230 V | 230 V | 230 V |
| 32 | Motor NP Frequency | 50 Hz | 50 Hz | 50 Hz | 50 Hz | 50 Hz | 50 Hz |
| 33 | Motor OL Current | 1.1 A | 1.1 A | 0.9 A | 0.9 A | 1.2 A | 1.2 A |
| 34 | Min Frequency | 0.0 Hz | 0.0 Hz | 0.0 Hz | 0.0 Hz | 0.0 Hz | 0.0 Hz |
| 35 | Max Frequency | 60 Hz | 60 Hz | 53 Hz | 53 Hz | 53 Hz | 53 Hz |
| 36 | Start Source | Comm Port | Comm Port | Comm Port | Comm Port | Comm Port | Comm Port |
| 37 | Stop Mode | Ramp CF | Ramp CF | Ramp CF | Ramp CF | Ramp CF | Ramp CF |
| 38 | Speed Reference | Comm Port | Comm Port | Comm Port | Comm Port | Comm Port | Comm Port |
| 39 | Acceleration Time 1 | 0.4 s | 0.4 s | 0.6 s | 0.6 s | 1.0 s | 1.0 s |
| 40 | Deceleration Time 1 | 0.1 s | 0.1 s | 0.6 s | 0.6 s | 1.0 s | 1.0 s |
| | | | | | | |
| Advanced Program | | | | | | | |
| 92 | Auto Restart | 2 | 2 | 2 | 2 | 2 | 2 |
| 105 | Comm Loss Action | Stop | Stop | Stop | Stop | Stop | Stop |
| | | | | | | |
| DeviceNet Module | | | | | | | |
| 169 | DN Address Config. | 3 | 4 | 11 | 12 | 5 | 6 |
| 171 | DN Rate Config. | 500 kbps | 500 kbps | 500 kbps | 500 kbps | 500 kbps | 500 kbps |
| 174 | Comm Fault Action | Stop | Stop | Stop | Stop | Stop | Stop |
| 175 | Idle Fault Action | Stop | Stop | Stop | Stop | Stop | Stop |
| 179 | COS Status Mask | 11111111 11111111 | 11111111 11111111 | 11111111 11111111 | 11111111 11111111 | 11111111 11111111 | 11111111 11111111 |
| | | DevNet 2 #7 | DevNet 1 #3 | DevNet 1 #4 | DevNet 3 #1 | DevNet 3 #2 |
| | Factory Settings | HEPA LFU (AD, SD, ASCM and Water) | Granulate Screw 1 | Granulate Screw 2 | TTCU Press Pump | TTCU Return Pump |
| Parameter Version 6 | Parameters 10.0 HP | 3 Ph, 10 HP | 3 Ph, 3 HP | 3 Ph, 10 HP | 3 Ph, 10 HP | 3 Ph, 15 HP | 3 Ph, 15 HP |
| Basic Program 31-43 | | | | | | | |
| 31 | Motor NP Voltage | 460 V | 400 V | 400 V | 400 V | 400 V | 400 V |
| 32 | Motor NP Frequency | 60 Hz | 50 Hz | 50 Hz | 50 Hz | 50 Hz | 50 Hz |
| 33 | Motor OL Current | 17.0 A | 4.6 A | 20.5 A | 20.5 A | 21.0 A | 14.5 A |
| 34 | Min Freq | 0.0 Hz | 0.0 Hz | 0.0 Hz | 0.0 Hz | 0.0 Hz | 0.0 Hz |
| 35 | Max Freq | 60 Hz | 60 Hz | 100 Hz | 100 Hz | 60 Hz | 60 Hz |
| 36 | Start Source | Keypad | Comm Port | Comm Port | Comm Port | Comm Port | Comm Port |
| 37 | Stop Mode | Ramp CF | Ramp CF | Ramp CF | Ramp CF | Ramp CF | Ramp CF |
| 38 | Speed Reference | Drive Pot | Comm Port | Comm Port | Comm Port | Comm Port | Comm Port |
| 39 | Acceleration Time 1 | 10.0 s | 10.0 s | 1.0 s | 1.0 s | 10.0 s | 10.0 s |
| 40 | Deceleration Time 1 | 10.0 s | 10.0 s | 1.0 s | 1.0 s | 10.0 s | 10.0 s |
| | | | | | | |
| Advanced Program | | | | | | | |
| 92 | Auto Restart | 0 | 2 | 3 | 3 | 3 | 3 |
| 105 | Comm Loss Action | Fault | Stop | Stop | Stop | Stop | Stop |
| | | | | | | |
| DeviceNet Module | | | | | | | |
| 169 | DN Address Config. | 63 | 7 | 3 | 4 | 1 | 2 |
| 171 | DN Rate Config. | Autobaud | 500 kbps | 500 kbps | 500 kbps | 500 kbps | 500 kbps |
| 174 | Comm Fault Action | Fault | Stop | Stop | Stop | Stop | Stop |
| 175 | Idle Fault Action | Fault | Stop | Stop | Stop | Stop | Stop |
| 179 | COS Status Mask | 00000000 00000000 | 11111111 11111111 | 11111111 11111111 | 11111111 11111111 | 11111111 11111111 | 11111111 11111111 |
Download from the Computer to the Scanner Module
Note: The DeviceNet Scanner module that is being loaded cannot be in RUN position during the loading.- Turn the key on the Logic CPU, to PROG mode position. The stopped scanner shows IDLE in the display.
- Click
Network (Online) to scan the network.Note: If necessary expand the navigation tree to select the correct Scanner module, mark it and then click OK if it is the first time a download is done. Click Save to save the path way to the Scanner in the project. - When the scanning is ready and the DeviceNet Scanner module is found (adr 00), right-click the module and select
Download to Device. - Wait until the download is finished.
- Close RSNetWorx.
- Turn the Scanner module to RUN position again.
DeviceNet - Load DeviceNet Configuration in a New or Rebuilt Point I/O ADN/DNB Module
| Equipment Status | Program Step step zero |
| Special Equipment | Computer with RSNetWorx Serial or network cable |
Personnel Requirements.Only authorised and skilled personnel are allowed to change the parameters.Changing the parameters can affect the machine in unexpected ways.
Description
The procedure describes how to install DeviceNet configuration in DNB scanner and ADN scanner after rebuilding a Point I/O node or to a new Point I/O node.Terminology
- DNB = the main scanners installed in the electrical cabinet (1756-DNB)
- ADN = the Point I/O scanners (1734-ADN)
- Download = Install configuration in a scanner from a computer
- Upload = Read information from a scanner to a computer
Work Flow
Preparations
The following preparations must be made:- DeviceNet files on the computer.
- Make sure that all NetWorx files are placed in the folder Networks, with the address: C:\200v Program\Projects\Networks
- Before working with the files, make a backup of them. Save the backup in another folder on the computer in case of any fault during download.
- If the files are saved to the address above the function Associated Network… in the NetWorx software can be used. Using this function it is possible to jump between the DNB DeviceNet file and the ADN files related to this file.
- Turn off the firewall.
- If there is a firewall installed on the computer, make sure that it is turned off.
- Turn off the Logic CPU.
- Set the Logic CPU in step program.
- The indicator run goes off.
- Download of the DeviceNet configuration can not be done when the CPU is in step run.
Turn OFF the Main Power Supply Disconnector
Before rebuilding the Point I/O node, make sure that all 24 V supply is turned off.Mains voltage:- Normal 24 V
- Class II 24 VNote: It is recommended to turn off the main power supply disconnector Q001.
Rebuild the Point I/O Node
- Assemble the Point I/O node according to the new drawing.
- Make sure to put the correct type of bottom slices in the correct places.
- Make sure that the sheet metal shields between the bottom slices have contact with each other.
- Make sure to put the correct type of I/O module in the correct bottom slice.
- Make sure that the interlocking side pieces are in the correct position.
Turn ON the Main Power Supply Disconnector
- Turn on both the 24 V mains voltage and the Point I/O 24 V supply.
- Make sure that the top green LED in the ADN scanner and all the I/O modules are lit.
- At this point the Pointbus status indicator on the ADN scanner will be lit with a red light because the node differs from the old configuration that still remains in the ADN scanner (for example one I/O module has been added).
Start an Empty Project in RSNetWorx
- Start the RSNetWorx software or open an existing DeviceNet file.
- Click New to open a new empty project.Note: The illustration shows an empty project.
Download an Empty Project to the ADN Scanner
An empty project must be downloaded to the ADN scanner in the rebuilt Point I/O node. This is done to prevent any data conflicts while downloading a new configuration to the ADN scanner.Note: This is not necessary to do when downloading to a new empty ADN scanner.- When a new project has been opened according to Start an Empty Project in RSNetWorx, click Network (Online).
- Click
Plus in the navigation tree to expand the path and browse for the ADN Point I/O module network symbol (Subnet). - Select the
ADN Point I/O module network symbol (Subnet) and click Ok.Note: It can take a while before the 1734-ADN Point I/O nodes are visible in the 1756 DNB scanner file structure. Wait until the correct node is visible before making the selection.Note: The illustration shows the path to node 20, Package L1.
- In the displayed information window, click
OK. Browsing network... starts.Note: The illustration shows all modules in Package L1.
- Right-click the
ADN Point I/O Scanner symbol and select Download to Device.Note: Download can only be done if the PLC is in step program (stopped).
The download starts.When the download is finished an empty project has been downloaded to the ADN scanner.- Click
Network to disconnect from the network.
- Click
Close to close the empty project.Note: It is not necessary to save the project.
Download an Empty Project to the DNB Scanner
An empty project must be downloaded to the DNB scanner that communicates with the ADN scanner in the rebuilt Point I/O. This is done to erase the content in the DNB scanner and prevent any data conflicts during download of a new configuration to the ADN scanner in the Point I/O node.Note: This is not necessary when downloading to a new empty DNB scanner.The tables below shows which nodes are connected to each DNB scanner.| DeviceNet1 (DNB scanner in position 3) | Addr 00, Baud 500 |
| Filling A | 09 |
| Filling B | 10 |
| Filling C USA * | 08 |
| Package 1 | 20 |
| Package 2 | 21 |
| N2S** | 40 |
| DeviceNet2 (DNB scanner in position 4) | Addr 00, Baud 500 |
| ASU | 10 |
| Carton IO L1 | 20 |
| Carton IO L2 | 21 |
| Carton Valves | 22 |
| LFU1 | 30 |
| LFU2 | 31 |
| CAU*** | 50 |
| DeviceNet3 (DNB scanner in position 12) | Addr 00, Baud 500 |
| TTCU | 10 |
* Variant USA/Canada** Optional equipment gas dosing system*** Variant XH with IC- When an empty project has been opened according to Start an Empty Project in RSNetWorx, click Network to point out where to download the project.
- Click
Plus in the navigation tree to expand the path. - Browse for the
Network symbol of the correct DNB module. - Select the
None symbol and click OK.Note: The illustration shows the path to the DNB scanner in position 3.
- In the displayed information window, click
OK. Browsing network... starts.
- When the
Browsing network... is finished all the nodes that the DNB scanner have established a contact with are displayed. The frequency converters will not be displayed since there is no power supply to them.Note: The illustration shows the nodes that the DNB scanner in position 3 has established a contact with.
- Right-click the
DNB scanner 00 and select Download.
- The download starts.
- When the download is finished an empty project has been downloaded to the DNB scanner.
Upload the Point I/O ADN Scanner to the Computer
An upload from the rebuilt or the new Point I/O must be done to find out which I/O modules that are assembled with the node. It is important that the power to the node is turned on and that all modules are assembled in the correct position.- Right-click on the
Point I/O node and select Properties.Note: The illustration shows Properties selected on the node 20 (Package L1).
- The window below is displayed.
- Select the tab
Parameters. - Click
Upload.
- When the upload is finished the following window is displayed.
Execute an Automatic Numbering of the I/O Modules to the Point I/O ADN Scanner
- Change the parameter
4 AutoAddress Backplane M, from Do Nothing to value 1 according to the illustration. - Click the
OK.
- The window
EDS Editor is displayed. - Click
Yes to download the change of the configuration.
- An automatic re-numbering of the node I/O modules beginning on number 1 from the first module after the ADN scanner is now executed.Note: The execution may take a while. Wait at least one minute for the execution to take place.
- If there are more Point I/O nodes connected to this DNB in need of re-numbering, repeat the procedure on these Point I/O nodes.
- When the re-numbering procedure is finished, click Network to disconnect from the network.
- Click
Close to close the empty project.Note: It is not necessary to save the project.
Connect to Point I/O ADN Scanner and Download the New Configuration
- Open the RSNetWorx file for which the node that the configuration will be downloaded.Note: The Package L1 that is used as an example in the , is also used as an example in this procedure.
- Open the Package L1 node.
- Click
Network (Online).
- Browse for the
None symbol (Subnet). - Select the
None symbol (Subnet) - Click
Ok.Note: It can take a while before the 1734-ADN Point I/O nodes are visible in the 1756 DNB scanner file structure. Wait until the correct node is visible before making the selection.Note: The illustration shows the path to node 20, Package L1.
- In the displayed information window, click
OK. Browsing network... starts.Note: The illustration shows all modules in Package L1.
- Make sure that the ADN scanner or any I/O module are not displayed with a red Missing symbol. The table below explains the symbols significance. If there are no Missing symbols or Mismatch symbols continue to item Reference. If turquoise Mismatch symbols are displayed continue to item Reference.
| Symbol | Denomination | Significance |
 | Mismatch | The identity information for the device shown in the network configuration is not the same as the identity information of the physical device. |
 | Missing | The device shown in the network configuration either is offline or it is not connected to the network. |
If the ADN scanner is marked with a Missing symbol it has not been found in the network. In this case take the following action:- Disconnect from the network.- Connect to the network again.- Check if the Missing symbol has gone off. - If the Missing symbol has not gone off:- Close the project.- Open the project.- Connect to the network.- Check if the Missing symbol has gone off. If neither of these actions makes the Missing symbol go off make sure that:- the node is connected.- the power to the node is turned on.- the node address is correct. It is also important to check that there are 121 Ohm termination resistors placed in the correct positions in the network. See Distributed I/O, table on page Distributed I/O.
If one or several modules are marked with Missing symbols the reasons can be that:- the automatic re-numbering procedure is not finished.- the bottom slices are not correctly installed, the sheet metal shields are not in contact with each other.In this case, disconnect from the network and then connect again.It may be necessary to close the project, open it again and then connect to the network. But first make sure that the bottom slices are correct installed.If this does not make the missing symbols go off, it is necessary to redo the automatic re-numbering procedure. Start over from Start an Empty Project in RSNetWorx.- If everything is correct, click Save to save the path to the node in the project and continue to Download the New ADN Configuration.Note: When browsing the next time it is not necessary to point out the whole path.
- If the ADN scanner is displayed with a turquoise Mismatch symbol, the project must be updated on the computer before a download can be made.
- Double-click on the ADN scanner marked as a mismatch.
- An information window is displayed containing information about the data configured in the project (Offline) and what the computer is connected to (Online).
- Make sure that the same product is stated Online and Offline and that it is only one revision difference that separates them. If this is the case go to Download the New ADN Configuration. If not continue to Difference in Product?.
Difference in Product?
Wrong Network
If there is a difference in product displayed, Online Identity = 1756-DNB, the wrong network is selected. The network for the DNB scanner is selected. The reason for the fault is that there has not been enough waiting time in order to let all the ADN modules become visible in the file structure.- Click
Cancel in the Mismatch window. - Disconnect from the network. Do not save anything in the project.
- Open the project again and connect in order to browse for the correct network (DeviceNet, Subnet, …).
- Click
OK to confirm the revision difference. - A new window for the ADN Point I/O scanner is displayed.
- Click
OK to update the project with the correct revision. - Click
Save to save the project change.
- Also double-click on the other I/O modules marked with a
Mismatch symbol.
- Before updating the project, make sure that the mismatch only depends on the revision difference.
- Click
Save to save the project change.
Wrong Module
If the mismatch depends on a difference in product, the wrong module is installed (Online) compared to what the project states (Offline).- Click
Cancel in the Mismatch window. - Disconnect from the network. Do not save anything in the project.
- If two modules have been varying, the automatic re-numbering is not correct and must be redone. Start over from Start an Empty Project in RSNetWorx.
Download the New ADN Configuration
- Right-click the
ADN Point I/O scanner symbol and select Download to Device.Note: Download can only be done if the PLC is in step program (stopped).
- Click
Yes to confirm the download.
- A download is executed.
- When the download is finished, click
Network to disconnect from the network.
- Click
Close to close the project for the Point I/O scanner.
Connect to DNB Scanner and Download the New Configuration
- Start the
DeviceNet1 or DeviceNet2 file for the DNB scanner that communicates with the ADN scanner that has been downloaded with a new configuration. See the table below. Note: The tables shows which nodes that are connected to each DNB scanner| DeviceNet1 (DNB scanner in position 3) | Addr 00, Baud 500 |
| Filling A | 09 |
| Filling B | 10 |
| Filling C USA* | 08 |
| Package 1 | 20 |
| Package 2 | 21 |
| N2S** | 40 |
| DeviceNet2 (DNB scanner in position 4) | Addr 00, Baud 500 |
| ASU | 10 |
| Carton IO L1 | 20 |
| Carton IO L2 | 21 |
| Carton Valves | 22 |
| LFU1 | 30 |
| LFU2 | 31 |
| CAU*** | 50 |
| DeviceNet3 (DNB scanner in position 12) | Addr 00, Baud 500 |
| TTCU | 10 |
* Variant USA/Canada** Optional equipment gas dosing system *** Variant XH with IC
- The illustration shows the
DeviceNet1 file for the DNB scanner in position 3 (without N2S node).
- Click
Network (Online) and browse for the None symbol.
- Select the
DNB module network symbol. - Click
Ok.
- In the displayed information window, click
Ok. Browsing network... starts.Note: All the F/C are displayed with Missing symbols because the power is not turned on.
- Make sure that the DNB scanner (00) is not displayed with a red
Missing symbol. The table below explains the symbols significance. If there are no Missing or Mismatch symbols continue to item Reference.| Symbol | Denomination | Significance |
 | Mismatch | The identity information for the device shown in the network configuration is not the same as the identity information of the physical device. |
 | Missing | The device shown in the network configuration either is offline or it is not connected to the network. |
Missing
If the DNB scanner is marked with a Missing symbol it has not been found in the network. In this case take the following action:- Disconnect from the network.
- Connect to the network again.
- Check if the
Missing symbol has gone off.
If the Missing symbol has not gone off:- Close the project.
- Open the project.
- Connect to the network.
- Check if the
Missing symbol has gone off.
Mismatch
If the DNB scanner is displayed with a turquoise Mismatch symbol, the project must be updated on the computer before a download can be made.- Double-click on the mismatch selected DNB scanner.- An information window is displayed containing information about what is installed (Online) and what the project is configured for (Offline).- Make sure that it is the same product stated Online and Offline and that it is only one revision difference that separates them. If there is a difference in product, first make sure that the correct network is selected for scanning. If a wrong type of DNB scanner module is installed, it must be replaced with the correct type.- Click Cancel in the Mismatch window.- Disconnect from the network.- Do not save anything in the project.- If the DNB module is the wrong type, replace it with the correct type of DNB module.- Click OK.- A new window for the DNB scanner is displayed.- Click OK to update the project with the correct revision.- If everything is correct click
Save to save the project change.
- Right-click on the
DNB scanner symbol and select Download to Device.Note: Download can only be done if the PLC is in step program (stopped).
- Click
Yes to confirm the download.
- A download is executed.
- When the download is finished, click
Network to disconnect from the network.
- Click
Close to close the project.
- Put the PLC back in step run.
- If you want to control the PLC from the computer wait 5 seconds and then turn the key to REM.
Start Up the System
Power cycle the system.- Turn off the 24 V power supply to:
- the Point I/O ADN scanner
- the EP 24 power module
- FPD power module
- Wait a few seconds and then turn on the power supply again.
- The node is correct when all the LED on the ADN scanner and the modules are lit with a green light.
- If the alarm Communication, Motion CPU <> logic CPU, time out occurs, reset the alarm.
- The window shown below will appear. See Section Start-up - Check Values in Power Failure - Start Up for more information.
DNB Module - Troubleshoot
The tables below describes how to troubleshoot the DNB Module. The module has a display and status indicator LED.The indicator LED are shown in the illustration.For explanation of the display codes see the table below.* The original troubleshooting information is found in publication “DNET-UM004A-EN-P - March 2004” from Rockwell Automation.
- Module/Network (Mod/Net) status indicator
- I/O Status indicator
- OK Status indicator
Display Codes
| Display | Description |
| A#xx | Address of this device, where: xx is the address. |
| IDLE | Device is in idle mode. |
| AUTO | The AutoScan option is on and the device is in idle mode. |
| RUN | Device is in run mode. |
| No Network Power | The DeviceNet cable is not supplying power to the communication port. |
| Network Disabled | Controller has set the device to the disabled mode. |
| No Rx | Either or both of the following:- The device does not have a scan list.- The device has not received communication from any other device |
| No Tx | Device has failed to transmit a message. |
| N#xx | Another device has a problem, where: xx is the address of the device. The status code for the device follows the address. |
| E#xx | Status code (page 12-16) for a device with a problem, where: xx is the status code for the device. The address of the device comes before the status code. |
Module/Network (Mod/NET) status indicator (1).
| State | Description | Recommended Action |
| OFF | - The device has not completed the Dup_MAC_ID test.- The device may not have power. | Make sure the device has power. |
| Solid green | Device is OK and is communicating with other devices on the network. | None |
| Flashing green | Device is OK but is not communicating with other devices on the network. | If the device is supposed to communicate with other devices, add those devices to the scan list of this device. |
| Flashing red | Either or both of the following:- Recoverable fault.- Communication with at least 1 device has timed out. | Check the 4-character display to determine if/which device has timed out. |
| Solid red | Any of the following:- Another device is using the same address.- Communication problems on the network (bus-off condition)- Device has an unrecoverable fault and may need to be replaced. | - Make sure the device has an unique address.- Make sure all devices are the same baud rate.- Cycle power to the device.- For more corrective actions, see status code 91. |
| Flashing red/green | Device is in self test. | None |
I/O Status Indicator (2)
| State | Description | Recommended Action |
| OFF | The DeviceNet cable is not supplying power to the communication port. | Apply network power. |
| Flashing green | The device is in idle mode and is not communicating with the devices on the network. | To control output devices, place the scanner in run mode. |
| Solid green | The device is in run mode and is communicating with the devices on the network. | None. |
OK Status Indicator (3)
| State | Description | Recommended Action |
| OFF | The device does not have power. | - Turn on power to the chassis.- Make sure the device is fully inserted into the chassis. |
| Flashing green | The device is OK but is not communicating with the controller. | Make sure that the device is correctly configured in the I/O configuration of the controller. |
| Solid green | The device is OK and communicating with the controller. | None. |
| Solid red | - The device is powering-up.- The device has an unrecoverable fault. | - Wait to verify that the device has completed its power-up sequence.- If the device appears to have completed its power up sequence, cycle power to the device.- Replace the device. |
Status Code
Status codes give you detailed information about the status or error of the scanner or another device on the network.| State | Description | Recommended Action |
| 65 | The AutoScan option is on and the device is in idle mode. | None |
| 70 | The address of the device is already in use by another device on the network. | Change the address of the device to an unused address. |
| 71 | Illegal data in scan list. | Reconfigure the scan list and remove any illegal data. |
| 72 | No communication with the device. | Inspect the device and verify connections. |
| 73 | Device’s identity information does not match electronic key in scanner | |
| 74 | Data overrun on port detected. | Modify your configuration and check for invalid data. Check network communication traffic. |
| 75 | Either or both of the following: - The device does not have a scan list. - The device has not received communication from any other device | Check that the device has:- Scan list- Properly wired connection to the network |
| 76 | No direct network traffic for scanner. | None. The scanner hears other network communication but does not hear any directed to it. |
| 77 | During initialization, the data size expected by the device does not match the scan list entry. | Check the device and the scan list for the correct input and output size for the device. |
| 78 | Device is not communicating or communication is intermittent. | - Check that the device has a properly wired connection to the network.- Check that the device has power.- If the device is polled, make sure the interscan delay is long enough for the device to return its data. |
| 79 | Scanner has failed to transmit a message. | - Make sure that your scanner is connected to a valid network. - Check for disconnected cables. |
| 80 | Scanner is in idle mode. | To run the network: - Put controller in run/remote run mode.- Turn on the following member of command register for the scanner:…O.CommandRegister.Run |
| 81 | Controller has set the scanner to the faulted mode. | See if the following bit of the command register for the scanner is on:. . .O.CommandRegister.Fault |
| 82 | Error detected in sequence of fragmented I/O messages from device. | - Check scan list device to make sure that its input and output data sizes are correct. - Check the configuration of the device. |
| 83 | Device returns error responses when the scanner attempts to communicate with it. | - Check the accuracy of the scan list.- Check the configuration of the device. The device may be in another scanner’s scan list. - Cycle power to the device. |
| 84 | Scanner is initializing the DeviceNet network. | None. This code clears itself once the scanner attempts to initialize all the devices on the network. |
| 85 | During runtime, the device is sending the wrong size of data. | Contact Rockwell Automation support. |
| 86 | Device is in idle state/mode (not producing data) while the scanner is in run mode. | - Check the configuration and status of the device. - If you set up an interlock between 2 scanners (controllers), make sure both scanners are in run mode. |
| 88 | In shared inputs, the I/O parameters (polled, strobed, etc.) do not match between the scanners. | Use the same I/O parameters for the device in both scanners. |
| 89 | Scanner failed to configure a device using the Automatic Device Recovery (ADR) parameters | Make sure that you installed a compatible device. The offline configuration for the device does not match the actual (online) configuration of the device. |
| 90 | Controller has set the scanner to the disabled mode. | See if the following bit of the command register for the scanner is on:. . . O.CommandRegister.DisableNetwork |
| 91 | Bus-off condition (communication problem) | - Cycle power to the device. Make sure all devices are at the same baud rate.- Make sure there is no short circuit between a CAN line (blue or white) and a power or shield line (black, red, shield).- Check for any of the following sources of noise: - Close proximity to a high voltage power cable- Improper or no termination resistor - Improper grounding - Check for a device that is producing noise or inappropriate data on the network. |
| 92 | The DeviceNet cable is not supplying power to the communication port. | - Make sure the network has 24V dc power.- Check the connection to the device. |
| 95 | The firmware of the device is currently being updated. | None. Do not disconnect the device while the update is in progress. You will lose any existing data in the device’s memory. |
| 96 | Communication port is in test mode. | None. |
| 97 | Controller has set the scanner to the halted mode. | - See if the following bit of the command register for the scanner is on:. . . O.CommandRegister.HaltScanner - Cycle power to the scanner. |
| 98 | General firmware error. | Replace device. |
| 99 | System failure. | Replace device. |
1734 ADN Module - Troubleshoot
The table below describes how to troubleshoot the ADN Module.The indicator LED are shown in the illustration.* The original troubleshooting information is found in publication 1734-UM002C-EN-P - July 2003 from Rockwell Automation.
- Adapter Status
- Network Status
- PointBus Status
- System Power
- Field Power
| Indicator | Indication | Probable Cause | Take This Action |
| System Power | Off | Any of the following:- Not active- Field power is OFF- DC-DC converter problem | - Check adapter configuration- Turn field power ON- Check DC-DC converter |
| Green | Any of the following:- System power ON- DC-DC converter active (5V) | None |
| Field Power | Off | Any of the following:- Not active- Field power is OFF | - Check adapter configuration- Turn field power ON |
| Green | Power ON, 24V present | None |
| Adapter Status | Off | No power applied to device | Power the adapter |
| Green | Device operating normally | None |
| Flashing Green | Device needs to be commissioned because configuration is missing, incomplete or incorrect | Check configuration and recommission the adapter |
| Flashing Red | Recoverable fault | Make sure the adapter does not need a FLASH update |
| Red | Unrecoverable fault may require device replacement | Replace the adapter |
| Flashing Red/Green | Device is in self-test | Wait for self-test to finish |
| Network Status | Off | - Device is not online- Device is autobauding - Device has not completed dup_MAC_id test- Device not powered | Check adapter status indicator to determine if more time is needed to complete the dup_MAC_id test or if the adapter needs to be powered |
| Flashing Green | Device is on-line but has no connections in the established state | None |
| Green | Device on-line and has connections in the established state | None |
| Flashing Red | One or more I/O connections in timed-out state | Determine the cause of the time-out. The EPR may need to be increased. |
| Red | Critical link failure - failed communication device. Device detected error that prevents it communicating on the network. | Make sure the device is using the correct MAC ID and baud rate |
| Subnet and PointBus Status | Off | - Device is not on-line- Device has not completed Dup_MAC_ID test.- Device not powered - check module status indicator | Check adapter status indicator to determine if more time is needed to complete the dup_MAC_id test or if the adapter needs to be powered |
| Flashing Green | Device is online but has no connections in the established state | None |
| Green | Device on-line and has connections in the established state. | None |
| Flashing Red | - No scanlist is available.- I/O module is missing. | - Make sure all I/O modules are connected and using the correct MAC IDs.- Check “Cycling Node Status” parameter in RSNetWorx for DeviceNet. |
| Red | Critical link failure - failed communication device. Device detected error that prevents it communicating on the network. | - Make sure an I/O module is not using a MAC ID =0.- Make sure all backplane modules are communicating at the proper baud rate. |
Frequency Converter - Troubleshoot
| Equipment Status | Power must be turn OFF.
|
The adapter uses three status indicators to report its operating status.They can be viewed through the drive cover.| Pos. | Status Indicator | Status1 | Description |
| 1 | port | Green | Normal operation. The adapter is properly connected and is communicating with the drive. |
| Flashing green | The adapter is in the process of establishing a connection to the drive. This status indicator will turn solid green or red. |
| 2 | mod | Green | Normal operation. The adapter is operational and is transferring I/O data. |
| Flashing green | Normal operation. The adapter is operational but is not transferring I/O data. |
| 3 | net a | Green | Normal operation. The adapter is properly connected and communicating on the network. |
| Flashing green | The adapter is properly connected but is not communicating with any devices on the network. |
| 4 | net b | Off | Not used for DeviceNet. |
| 1) If all status indicators are off, the adapter is not receiving power. |
The table below describes how to troubleshoot a PowerFlex40 (PF40) frequency drive.| No. | Fault | | Description | Action |
| F2 | Auxiliary Input | 1* | Auxiliary input interlock is open. | - Check remote wiring.- Verify communications programming for intentional fault. |
| F3 | Power Loss | 2* | DC bus voltage remained below 85% of nominal. | - Monitor the incoming AC line for low voltage or line power interruption.- Check input fuses. |
| F4 | UnderVoltage | 1* | DC bus voltage fell below the minimum value. | Monitor the incoming AC line for low voltage or line power interruption. |
| F5 | OverVoltage | 1* | DC bus voltage exceeded maximum value. | Monitor the AC line for high line voltage or transient conditions. Bus overvoltage can also be caused by motor regeneration. Extend the decel time or install dynamic brake option. |
| F6 | Motor Stalled | 1* | Drive is unable to accelerate motor. | Increase P039 - A067 (Accel Time x) or reduce load so drive output current does not exceed the current set by parameter A089 (Current Limit 1). |
| F7 | Motor Overload | 1* | Internal electronic overload trip. | - An excessive motor load exists. Reduce load so drive output current does not exceed the current set by parameter P033 (Motor OL Current).- Verify A084 (Boost Select) setting |
| F8 | Heatsink OvrTmp | 1* | Heatsink temperature exceeds a predefined value. | - Check for blocked or dirty heat sink fins. Verify that ambient temperature has not exceeded 40×C (104×F) for IP30, NEMA UL Type 1 installations or 50×C (122×F) for IP20/Open type installations.- Check fan. |
| F12 | HW OverCurrent | 2* | The drive output current has exceeded the hardware current limit. | Check programming. Check for excess load, improper A084 (Boost Select) setting, DC brake volts set too high or other causes of excess current. |
| F13 | Ground Fault | 2* | A current path to earth ground has been detected at one or more of the drive output terminals. | Check the motor and external wiring to the drive output terminals for a grounded condition. |
| F29 | Analog Input Loss | 1* | An analog input is configured to fault on signal loss. A signal loss has occurred.Configure with A122 (Analog In Loss). | - Check parameters.- Check for broken/loose connections at inputs. |
| F33 | Auto Rstrt Tries | 2* | Drive unsuccessfully attempted to reset a fault and resume running for the programmed number of A092 (Auto Rstrt Tries). | Correct the cause of the fault and manually clear. |
| F38 | Phase U to Gnd | 2* | Drive unsuccessfully attempted to reset a fault and resume running for the programmed number of A092 (Auto Rstrt Tries).A phase to ground fault has been detected between the drive and motor in this phase. | - Check the wiring between the drive and motor.- Check motor for grounded phase.Replace drive if fault cannot be cleared. |
| F39 | Phase V to Gnd | |
| F40 | Phase W to Gnd | |
| F41 | Phase UV Short | 2* | Excessive current has been detected between these two output terminals. | -Check the motor and drive output terminal wiring for a shorted condition. - Replace drive if fault cannot be cleared. |
| F42 | Phase UW Short | |
| F43 | Phase VW Short | |
| F48 | Params Defaulted | | The drive was commanded to write default values to EEPROM. | - Clear the fault or cycle power to the drive.- Program the drive parameters as needed. |
| F63 | SW OverCurrent | 1* | Programmed A098 (SW Current Trip) has been exceeded. | Check load requirements and A098 (SW Current Trip) setting. |
| F64 | Drive Overload | 2* | Drive rating of 150% for 1 minute or 200% for 3 seconds has been exceeded. | Reduce load or extend Accel Time. |
| F70 | Power Unit | 2* | Failure has been detected in the drive power section. | - Cycle power. - Replace drive if fault cannot be cleared. |
| F71 | Net Loss | | The communication network has faulted. | - Cycle power.- Check communications cabling.- Check network adapter setting.- Check external network status. |
| F80 | SVC Autotune | | The autotune function was either cancelled by the user or failed. | Restart procedure. |
| F81 | Comm Loss | 2* | RS485 (DSI) port stopped communicating. | - If adapter was not intentionally disconnected, check wiring to the port. Replace wiring, port expander, adapters or complete drive as required.- Check connection.- An adapter was intentionally disconnected.- Turn off using A105 (Comm Loss Action). |
| F100 | Parameter Checksum | 2* | The checksum read from the board does not match the checksum calculated. | Set P041 (Reset To Defaults) to option 1 “Reset Defaults”. |
| F122 | I/O Board Fail | 2* | Failure has been detected in the drive control and I/O section. | - Cycle power.- Replace drive if fault cannot be cleared. |
| Fault Description | | | |
| 1* = Auto-Reset/Run | When this type of fault occurs, and A092 (Auto Rstrt Tries) is set to a value greater than “0,” a user-configurable timer, A093 (Auto Rstrt Delay), begins. When the timer reaches zero, the drive attempts to automatically reset the fault. If the condition that caused the fault is no longer present, the fault will be reset and the drive will be restarted. |
| 2* = Non-Resetable | This type of fault may require drive or motor repair, or is caused by wiring or programing errors. The cause of the fault must be corrected before the fault can be cleared. |
Frequency Converter - Troubleshoot
| Equipment Status | Power must be turn OFF.
|
The condition or state of your drive is constantly monitored. Any changes will be indicated through the integral LCD display.The LCD display and the basic functions of the buttons of the Powerflex 525 are described below.| Key | Name | Description |
  | Up ArrowDown Arrow | Scroll through user-selectable display parameters or groups.Increment values. |
 | Escape | Back one step in programming menu.Cancel a change to a parameter value and exit Program Mode. |
 | Select | Advance one step in programming menu.Select a digit when viewing parameter value. |
 | Enter | Advance one step in programming menu.Save a change to a parameter value. |
| Menu | Parameter Group and Description |
 | Basic DisplayCommonly viewed drive operating conditions. |
|
 | Basic Program |
| Commonly used programmable functions. |
 | Terminal Blocks |
| Programmable terminal functions. |
 | Communications |
| Programmable communication functions. |
 | Logic |
| Programmable logic functions. |
 | Advanced Display |
| Advanced drive operating conditions. |
 | Advanced Program |
| Remaining programmable functions. |
 | Network |
| Network functions that are shown only when a comm card is used |
 | Modified |
| Functions from the other groups with values changed from default. |
 | Fault and Diagnostic |
| Consists of list of codes for specific fault conditions. |
 | AppView and CustomView |
| Functions from the other groups organized for specific applications. |
FaultsA fault is a condition that stops the drive. There are two fault types.Fault Types| Type | Fault Description | |
| 1 | Auto-Reset/Run | When this type of fault occurs, and A541 [Auto Rstrt Tries] is set to a value greater than “0,” a user-configurable timer, A542 [Auto Rstrt Delay], begins. When the timer reaches zero, the drive attempts to automatically reset the fault. If the condition that caused the fault is no longer present, the fault will be reset and the drive will be restarted. |
| 2 | Non-Resettable | This type of fault may require drive or motor repair, or is caused by wiring or programming errors. The cause of the fault must be corrected before the fault can be cleared. |
Fault Indication| Display | Condition |
 | Drive is indicating a fault.The integral LCD display provides visual notification of a fault condition by displaying the following.- Flashing fault number
- Flashing fault indicator (LED)
Press the Esc key to regain control of the display. |
|
Manually Clearing Faults| Keys | Step |
 | Press ESC to acknowledge the fault. The fault information will be removed so that you can use the integral keypad. Access b007 [Fault 1 Code] to view the most recent fault information.Address the condition that caused the fault. See table for fault types.After corrective action has been taken, clear the fault by one of these methods.- Press Stop if P045 [Stop Mode] is set to a value between “0” and “3”.
- Cycle drive power.
- Set A551 [Fault Clear] to 1 “Reset Fault” or 2 “Clear Buffer”.
- Cycle digital input if t062, t063, t065...t068 [DigIn TermBlk xx] is set to 13 “Clear Fault”.
|
|
Automatically Clearing Faults | Option/Step |
| Clear a Type 1 fault and restart the drive.- Set A541 [Auto Rstrt Tries] to a value other than “0”.
- Set A542 [Auto Rstrt Delay] to a value other than “0”.
Clear an OverVoltage, UnderVoltage or Heatsink OvrTmp fault without restarting the drive.- Set A541 [Auto Rstrt Tries] to a value other than “0”.
- Set A542 [Auto Rstrt Delay] to “0”.
|
|
Auto Restart (Reset/Run)The Auto Restart feature provides the ability for the drive to automatically perform a fault reset followed by a start attempt without user or application intervention. This allows remote or “unattended” operation. Only certain faults are allowed to be reset. Certain faults (Type 2) that indicate possible drive component malfunction are not resettable. Fault types are listed in the table Fault Types. See Fault Descriptions for more information.Use caution when enabling this feature, since the drive will attempt to issue its own start command based on user selected programming.| Display | LED State | Description |
| FAULT | Flashing Red | Indicates drive is faulted. |
The table below describes how to troubleshoot a PowerFlex525 (PF525) frequency drive.| No. | Fault | Type 2 | Description | Action |
| F000 | No Fault | - | No fault present. | - |
| F002 | Auxiliary Input | 1 | External trip (Auxiliary) input. | - Check remote wiring.
- Verify communications programming for intentional fault.
|
| F003 | Power Loss | 2 | Single phase operation detected with excessive load. | - Monitor the incoming AC line for low voltage or line power interruption.
- Check input fuses.
- Reduce load.
|
| F004 | UnderVoltage | 1 | DC bus voltage fell below the minimum. | Monitor the incoming AC line for low voltage or line power interruption. |
| F005 | OverVoltage | 1 | DC bus voltage exceeded maximum | Monitor the AC line for high line voltage or transient conditions. Bus overvoltage can also be caused by motor regeneration. Extend the decel time or install dynamic brake option. |
| F006 | Motor Stalled | 1 | Drive is unable to accelerate or decelerate motor. | - Increase P041, A442, A444, A446 [Accel Time x] or reduce load so drive output current does not exceed the current set by parameter A484, A485 [Current Limit x] for too long.
- Check for overhauling load.
|
| F007 | Motor Overload | 1 | Internal electronic overload trip. | - An excessive motor load exists Reduce load so drive output current does not exceed the current set by parameter P033 [Motor OL Current].
- Verify A530 [Boost Select] setting.
|
| F008 | Heatsink OvrTmp | 1 | Heatsink/Power Module temperature exceeds a predefined value. | - Check for blocked or dirty heat sink fins. Verify that ambient temperature has not exceeded the rated ambient temperature.
- Check fan.
|
| F009 | CC OvrTmp | 1 | Control module temperature exceeds a predefined value. | - Check product ambient temperature.
- Check for airflow obstruction.
- Check for dirt or debris.
- Check fan.
|
| F012 | HW OverCurrent | 2 | The drive output current has exceeded the hardware current limit. | Check programming. Check for excess load, improper A530 [Boost Select] setting, DC brake volts set too high or other causes of excess current. |
| F013 | Ground Fault | 1 2 | A current path to earth ground has been detected at one or more of the drive output terminals. | Check the motor and external wiring to the drive output terminals for a grounded condition. |
| F015 | Load Loss | 2 | The output torque current is below the value programmed in A490 [Load Loss Level] for a time period greater than the time programmed in A491 [Load Loss | - Verify connections between motor and load.
- Verify level and time requirements
|
| F021 | Output Ph Loss | 1 | Output Phase Loss (if enabled).Configure with A557 [Out Phas Loss En]. | - Verify motor wiring.
- Verify motor.
|
| F029 | Analog In Loss | 1 | An analog input is configured to fault on signal loss. A signal loss has occurred. Configure with t094 [Anlg In V Loss] or t097 [Anlg In mA Loss]. | - Check for broken/loose connections at inputs.
- Check parameters.
|
| F033 | Auto Rstrt Tries | 2 | Drive unsuccessfully attempted to reset a fault and resume running for the programmed number of A541 [Auto Rstrt Tries]. | Correct the cause of the fault and manually clear. |
| F038 | Phase U to Gnd | 2 | A phase to ground fault has been detected between the drive and motor in this phase. | - Check the wiring between the drive and motor
- Check motor for grounded phase.
- Replace drive if fault cannot be cleared
|
| F039 | Phase V to Gnd | |
| F040 | Phase W to Gnd | |
| F041 | Phase UV Short | 2 | Excessive current has been detected between these two output terminals. | - Check the motor and drive output terminal wiring for a shorted condition.
- Replace drive if fault cannot be cleared.
|
| F042 | Phase UW Short | |
| F043 | Phase VW Short | |
| F048 | Params Defaulted | 1 | The drive was commanded to write default values to EEPROM. | - Clear the fault or cycle power to the drive.
- Program the drive parameters as needed
|
| F059 1 | Safety Open | 1 | Both of the safety inputs (Safety 1, Safety 2) are not enabled. Configure with t105 [Safety Open En]. | Check safety input signals. If not using safety, verify and tighten jumper for I/O terminals S1, S2 and S+ |
| F063 | SW OverCurrent | 1 | Programmed A486, A488 [Shear Pinx Level] has been exceeded for a time period greater than the time programmed in A487, A489 [Shear Pin x Time]. | - Verify connections between motor and load.
- Verify level and time requirements.
|
| F064 | Drive Overload | 2 | Drive overload rating has been exceeded. | Reduce load or extend Accel Time. |
| F070 | Power Unit | 2 | Failure has been detected in the drive power section. | - Check maximum ambient temperature has not been exceeded.
- Cycle power.
- Replace drive if fault cannot be cleared.
|
| F071 | DSI Net Loss | 2 | Control over the Modbus or DSIcommunication link has been interrupted. | - Cycle power.
- Check communications cabling.
- Check Modbus or DSI setting.
- Check Modbus or DSI status.
|
| F072 | Opt Net Loss | 2 | Control over the network option card’s remote network has been interrupted. | - Cycle power.
- Check communications cabling.
- Check network adapter setting.
- Check external network status.
|
| F073 1 | EN Net Loss | 2 | Control through the embedded EtherNet/IP adapter has been interrupted. | - Cycle power.
- Check communications cabling.
- Check EtherNet/IP setting.
- Check external network status.
|
| F080 | Autotune Failure | 2 | The autotune function was either cancelled by the user or failed. | Restart procedure. |
| F081 | DSI Comm Loss | 2 | Communications between the drive and the Modbus or DSI master device have been interrupted. | - Cycle power.
- Check communications cabling.
- Check Modbus or DSI setting.
- Check Modbus or DSI status.
- Modify using C125 [Comm Loss Action].
- Connecting I/O terminals C1 and C2 to ground may improve noise immunity.
- Replace wiring, Modbus master device, or control module.
|
| F082 | Opt Comm Loss | 2 | Communications between the drive and the network option card have been interrupted. | - Cycle power.
- Reinstall option card in drive.
- Modify using C125 [Comm Loss Action].
- Replace wiring, port expander, option card, or control module.
|
| F083 1 | EN Comm Loss | 2 | Internal communications between the drive and the embedded EtherNet/IP adapter have been interrupted. | - Cycle power.
- Check EtherNet/IP setting.
- Check drive’s Ethernet settings and diagnostic parameters.
- Modify using C125 [Comm Loss Action].
- Replace wiring, Ethernet switch, or control module
|
| F091 | Encoder Loss | 2 | Requires differential encoder. One of the 2 encoder channel signals is missing. | - Check Wiring.
- If P047, P049, P051 [Speed Referencex] = 16 “Positioning” and A535 [Motor Fdbk Type] = 5 “Quad Check”, swap the Encoder channel nputs or swap any two motor leads.
- Replace encoder.
|
| F094 | Function Loss | 2 | “Freeze-Fire” (Function Loss) input is inactive, input to the programmed terminal is open. | Close input to the terminal and cycle |
| F100 | Parameter Chksum | 2 | Drive parameter non-volatile storage is corrupted. | Set P053 [Reset To Defalts] to 2 “Factory Rset”. |
| F101 | External Storage | 2 | External non-volatile storage has failed. | Set P053 [Reset To Defalts] to 2 “Factory Rset” |
| F105 | C Connect Err | 2 | Control module was disconnected while drive was powered | Clear fault and verify all parameter settings. Do not remove or install the control module while power is applied. |
| F106 | Incompat C-P | 2 | The PowerFlex 525 control module does not support power modules with 0.25 HP power rating. | - Change to a different power module.
- Change to a PowerFlex 523 control module
|
| F107 | Replaced C-P | 2 | The control module could not recognize the power module. Hardware failure. | - Change to a different power module.
- Replace control module if changing power module does not work
|
| F109 | Mismatch C-P | 2 | The control module was mounted to a different drive type power module. | Set P053 [Reset To Defalts] to 3 “Power Reset”. |
| F110 | Keypad Membrane | 2 | Keypad membrane failure / disconnected. | - Cycle power.
- Replace control module if fault cannot be cleared.
|
| F111 | Safety Hardware | 2 | Safety input enable hardware malfunction. One of the safety inputs is not enabled. | - Check safety input signals. If not using safety, verify and tighten jumper for I/O terminals S1, S2 and S+
- Replace control module if fault cannot be cleared.
|
| F114 | uC Failure | 2 | Microprocessor failure. | - Cycle power
- Verify grounding requirements. See General Grounding Requirements on page 20 for more information.
- Replace control module if fault cannot be cleared.
|
| F122 | I/O Board Fail | 2 | Failure has been detected in the drive control and I/O section. | - Cycle power.
- Replace drive or control module if fault cannot be cleared.
|
| F125 | Flash Update Req | 2 | The firmware in the drive is corrupt, mismatched, or incompatible with the hardware. | Perform a firmware flash update operation to attempt to load a valid set of firmware. |
| F126 | NonRecoverablErr | 2 | A non-recoverable firmware or hardware error was detected. The drive was automatically stopped and reset. | - Clear fault or cycle power to the drive
- Replace drive or control module if fault cannot be cleared.
|
| F127 | DSIFlashUpdatReq | 2 | A critical problem with the firmware was detected and the drive is running using backup firmware that only supports DSI communications. | Perform a firmware flash update operation using DSI communications to attempt to load a valid set of firmware. |
1 See Fault Types for more information.2 This fault may be cleared by the auto-restart routine and will be attempted only once. It ignores the value set in parameter A541 [Auto Rstrt Tries].Servo System
Note: Series mismatch. When replacing a component that contains firmware, it is important that the components have the same series as the old ones.Note: Revision mismatch. It might be possible to use a component with a new revision, but it is recommended to use the same revision as the old one.The series and revision is printed on the component.Functional Description
The PLC system handles all functions for controlling the servomotors in the machine. The Logic CPU executes the logic functions of the machine, that is, stepping up and down and the actions of pneumatic actuators, alarms and so on. The Motion CPU executes the parts in the machine concerning motion, that is controlling the servomotors. The logic CPU and the motion CPU exchange information regarding ladder position, alarms, volume and bottom format.The Motion CPU communicates with the servo control cards, called Sercos card 1 and Sercos card 2 through the Backplane of the PLC rack.The Sercos card 1 and Sercos card 2 communicates through an Optical fibre network with the Servo rack containing the power supply and the Servo drive.Through the Power cable the drive provides power to the Servomotor and the motor position is sent to the drive through the Feedback cable.If the connected motor is equipped with a mechanical brake the brake function is integrated in the Power cable.
- PLC system
- CPULogic
- CPUMotion
- Sercos card 1
- Sercos card 2
- Backplane
- Optical fibre network
- Servo rack
- Servo drive
- Power cable
- Servomotor
- Feedback cable
Sercos Card
Sercos is a fibre-optic communication standard used for motion control. There are two Sercos cards in the TT/3 machine, Sercos card (A9205) and Sercos card (A9206) which control the Servo rack of servo drives (10 Additional servo drives for variant XH with IC).The Sercos cards and the drives are connected in a ring topology, see the illustration below. The card transmits data from the Sercos transmit (Tx) port of the card or the drive, and receives data on the Sercos receive (Rx) port of the card or the drive. These ports are located on top of the drives, and on the bottom of the Sercos cards. For further information see section Sercos Card, page Sercos Card.
- Sercos card (A9205)
- Sercos card (A9206)
- Sercos transmit (Tx)
- Sercos receive (Rx)
- Servo rack
- Additional servo drives for variant XH with IC
Communication between the cards and the drives is performed at a certain speed, called baud rate. The DIP switch settings on the drives and software settings on the Sercos cards determine the baud rate. For further information see section Servo Drive - Set Baud Rate.
Baud rate settings DIP switch
- DIP switch
Servo Rack
The Integrated Axis Module IAM provides power to the Servo drive in the Servo rack, and at the same time serves as a drive to one servomotor.Each rack has a base node number, which is set by two Switch on the IAM.The rack is powered with 400 VAC at the Power connector on top of the IAM to run the servomotors.Control power (240 VAC) to the drives in the rack is supplied through the Control power connector on top of the IAM.A DC bus provides the drives in the rack with DC power through the backplane. If a slot in the rack is empty, a Slot filler, which prevents access to the DC bus power bar, is installed.
Front view of the IAM.

Top view of the IAM.
- Servo rack
- IAM
- Servo drive
- Slot filler
- Switch
- Power connector
- Control power connector
The illustration below shows the function of each servo drive, the node number, and the reference designation number of the servo drives and the cables.Servo Drive
Each servo drive has a node number which is determined by the base node number set on the IAM and numbered depending on which rack-slot the drive is located in. The seven segment Fault status LED on the drive shows different code sequences depending on the status of the drive:- When the mains power is switched ON, the digits 1 and 2 are alternated. This is when parameters are sent from the Sercos card to the drives.
- When displaying 3 a check is made to determine that the correct servomotor is connected to the drive.
- At 4 the system is running.
Errors are displayed as an error message containing the letter E followed by two digits. An example of an error message sequence is E19: E – dark – 1 – dark – 9. This is the error code when the drive has tripped for Position error. For more information about the error codes, see Servo System - General Troubleshoot on page Servo System - General Troubleshoot.
Front view of the drive.
- LEDFault status
There are three more LED showing the status of the drive.- The upper LED, Drive Status, is OFF in normal condition and red if there is a fault.
- The middle LED, COMM Status, is OFF when there is no communication, that is when the fibre optic connection is loose, broken or incorrect connected. It flashes green when establishing communication and shows steady green when communication is established.
- The lower LED, Bus Status, is OFF when there is no bus power present. It flashes green when bus power is present but the axis is disabled and shows steady green when bus power is present and the axis is enabled.
On the bottom of the drive there are three D-sub connectors. 
Front view of the drive.
- 26-PIN D-sub connector for I/O communication
- 15-PIN D-sub connector for position feedback
- 15-PIN D-sub connector (not used in TT/3)
- LED
Connectors for Motor power and power to the mechanical brake of the motor Brake power are located on top of the drive. The baud rate setting DIP switch and the Tx and Rx-Sercos ports are also located here.
Top view of the drive.
- Motor power
- Brake power
- DIP switch
- Tx and Rx-Sercos ports
Servomotor
The servomotor has two connections: 
- Feedback connector
- Power connector with integrated brake (optional)
Servo System Troubleshooting
Servo System - General Troubleshoot
| Equipment Status | Program Step |
Refer to the error codes section below to identify problems, potential causes, and appropriate actions to resolve the problems. If problems persist after attempting to troubleshoot the system, please contact your Rockwell Automation representative for further assistance. To determine if your Kinetix 6000 drive has an error, refer to the table below.| In the Logic Power LED is ON and the Status LED display on your: | Is: | Then: |
| 2094-xCxx-Mxx IAM | Actively cycling segments in a full circle. | Your Kinetix 6000 is ready, but SERCOS communications is not available. |
| Displaying a fixed 4. | Your Kinetix 6000 drive is ready. |
| All drives | Flashing “E” followed by two numbers. | Your Kinetix 6000 drive has an error. Proceed to the section Error Codes below. |
Error Code
The following list of problematic symptoms (no error code shown) and problems with assigned error codes is designed to help you resolve problems.When a fault is detected, the 7-segment LED will display an E followed by the flashing of the two-digit error code, one digit at a time. This is repeated until the problem is cleared.| Error code | Fault messageRSLogix (HIM) | Problem or symptom | Possible cause(s) | Action/solution |
| | | Power (PWR) indicator not ON | No AC power or auxiliary logic power. | Verify AC control power is applied to the Kinetix 6000. |
| Internal power supply malfunction. | Call your Rockwell Automation sales representative to return module for repair. |
| | | Motor jumps when first enabled. | Motor wiring error. | - Check motor wiring. - Run Hookup test in RSLogix 5000. |
| Incorrect motor chosen. | Verify the proper motor is selected. |
| | | Digital I/O not working correctly | I/O power supply disconnected. | Verify connections and I/O power source. |
| E00 | BusUndervoltageFault(Blown fuse) | A blown fuse was detected on the inverter PCB. | Blown fuse. | Call your Rockwell Automation sales representative to return module for repair. |
| E04 | MotorOvertemp Fault(Motor Overtemp) | Motor thermal switch tripped | - High motor ambient temperature and/or excessive current. | - Operate within (not above) the continuous torque rating for the ambient temperature (40 °C maximum). - Lower ambient temperature, increase motor cooling. |
| Motor wiring error. | Check motor wiring at MF connector on the IAM/AM. |
| Incorrect motor selection. | Verify the proper motor has been selected. |
| E05 | DriveOvercurrent Fault (Power Fault) | Self-protection of the Intelligent Power Module (IPM) is indicating a major power related fault condition. | Motor cables shorted. | Verify continuity of motor power cable and connector. |
| Motor winding shorted internally. | Disconnect motor power cables from the motor. If the motor is difficult to turn by hand, it may need to be replaced. |
| Kinetix 6000 temperature too high. | - Check for clogged vents or defective fan. - Ensure cooling is not restricted by insufficient space around the unit. |
| Operation above continuous power rating and/or product environmental ratings. | - Verify ambient temperature is not too high. - Operate within the continuous power rating. - Reduce acceleration rates. |
| Kinetix 6000 has a short circuit, overcurrent, or failed component. | Remove all power and motor connections, and preform a continuity check from the DC bus to the U, V, and W motor outputs. If a continuity exists, check for wire fibres between terminals, or send drive in for repair. |
| E06 | HardOvertravel Fault(+/- Hard Overtravel) | Axis moved beyond the physical travel limits in the positive/negative direction. | Dedicated overtravel input is inactive. | - Check wiring. - Verify motion profile. - Verify axis configuration in software. |
| E07 | MotFeedbackFault(Motor Feedback Loss) | The feedback wiring is open, shorted, or missing. | - Check motor encoder wiring. - Run Hookup test in RSLogix 5000. |
| E09 | BusUndervoltage Fault(Bus Under Voltage) | With three-phase power present, the DC bus voltage is below limits. | - DC bus voltage for 460V system is below 275V - DC bus voltage for 230V system is below 137V | - Verify voltage level of the incoming AC power - Check AC power source for glitches or line drop. - Install an uninterruptible power supply (UPS) on your AC input. |
| DC bus voltage fell below the undervoltage limit while an axis on the follower power rail was enabled. | Disable follower axis before removing power. | |
| E10 | DriveOvervoltage Fault(Bus Overvoltage) | The DC bus voltage is above limits. | Excessive regeneration of power.When the motor is driven by an external mechanical power source, it may regenerate too much peak energy through the Kinetix 6000’s power supply. The system faults to save itself from an overload. | - Change the deceleration or motion profile. - Use a larger system (motor and Kinetix 6000). - Install shunt module. |
| - DC bus voltage for 460V system is over 820V - DC bus voltage for 230V system is over 410V | Verify input is within specifications. |
| E11 | MotFeedbackFault(Illegal Hall State) | State of Hall feedback inputs is incorrect. | Bad connections. | - Verify the Hall wiring at the MF connector on the IAM/AM. - Verify 5V power supply to the encoder. |
| E16 | SoftovertravelFault(+/- Software Overtravel) | Axis position exceeded maximum software setting. | - Verify motion profile. - Verify overtravel settings are appropriate. |
| E18 | OverSpeedFault(Overspeed Fault) | Motor speed has exceeded 150% of maximum rated speed. The 100% trip point is dictated by the lesser of the user velocity limits or the motor rated base speed. | - Check cables for noise. - Check tuning. |
| E19 | PositionErrorFault(Follow Error) | Position error limit was exceeded. | - Increase the feed forward gain. - Increase following error limit or time. - Check position loop tuning. - Verify sizing of system. - Verify mechanical integrity of system within specification limits. |
| E20 | MotFeedbackFault(Mtr Fdbk AQB) | Motor Encoder State Error | The motor encoder encountered an illegal transition. | - Use shielded cables with twisted pair wires. - Route the feedback away from potential noise sources. - Check the system grounds. - Replace the motor/encoder. |
| E21 | AuxFeedback Fault(Aux Feedback Comm) | Communication was not established with an intelligent encoder. | Verify auxiliary encoder wiring. |
| E30 | MotFeedbackFault(Motor Feedback Comm) | Communication was not established with an intelligent encoder. | - Verify motor selection. - Verify the motor supports automatic identification. - Verify motor encoder wiring. |
| E31 | DriveHardFault | Excessive motor shaft movement during power up, SERCOS ring phase-up, or after a fault reset. | Make sure there is no motor shaft movement during power up, SERCOS ring phase-up, or during a fault reset. |
| E34 | GroundShortFault(Ground Fault) | Excessive ground current in the converter was detected. | Wiring error. | - Check motor power wiring. - Check input power wiring (refer to Kinetix 6000 Installation Manual, publication 2094-IN001x-EN-P, regarding use of isolation transformer). |
| Motor internal ground short. | Replace motor. |
| Internal malfunction. | Disconnect motor power cable from drive and enable drive with current limit set to 0. If fault clears, then a wiring error or motor internal problem exists. If fault remains, call your A-B representative. |
| Grounded control power terminal.(Applies to 230V system) only) | - Remove ground from control power input. - Source control power from three-phase input power. - Add isolation transformer for control power. |
| E35 | DriveUndervoltage Fault(Precharge Fault) | Converter pre-charge cycle failed. | Low AC input voltage. | Check input AC voltage on all phases. |
| Internal malfunction. | Call your sales representative. |
| E36 | DriveOvertemp Fault(System Overtemperature) | Converter thermal switch tripped. | Excessive heat exists in the power circuitry. | - Reduce acceleration rates. - Reduce duty cycle (ON/OFF) of commanded motion. - Increase time permitted for motion. - Use larger Kinetix 6000 converter. - Check for clogged vents or defective fan. - Ensure cooling is not restricted by insufficient space around the unit. |
| E37 | PowerPhaseLossFault(Phase Loss Fit) | - One or more phases of the input AC power is missing. - Axis was enabled when main (3-phase) power was removed..- Common bus follower axis was enabled when DC bus power was removed. | - Check input AC voltage on all phases. - Disable axis before removing power. |
| E38 | SERCOSFault(SERCOS Ring Flt) | The SERCOS ring is not active after being active and operational. | Cable disconnected. | Check that the fibre-optic cable is present and connected properly. |
| E39 | DriveHardFault(Self Sense Flt) | Self-sensing Commutation Startup Error. | Motion required for self-sensing strartup commutation was obstructed. | - Verify that there are no impediments to motion at start up, such as hard limits. - Increase self-sensing current if high friction or load conditions exist.- Check motor or encoder wiring using wiring diagnostics. |
| E43 | DriveEnableInput(Drive Enable Flt) | Missing Drive Enable Input Signal | - An attempt was made to enable the axis through software while the Drive Enable hardware input was inactive. - The Drive Enable input transitioned from active to inactive while the axis was enabled. | - Disable the Drive Enable Input fault. - Verify that Drive Enable hardware input is active whenever the drive is enabled through software. |
| E49 | DriveHardFault(Safe-Off HW flt) | Safe-off functionmismatch. Drive will not allow motion. | - Loose wiring at SO connector. - Cable/header not seated properly in SO connector. - Safe-off circuit missing +24V dc. | - Verify wire terminations, cable/header connections, and +24V. - Reset error and run proof test. - If error persists, return the drive to Rockwell Automation. |
| E50 | SERCOSFault(Sercos Same ADDR) | Duplicate node address detected on SERCOS ring. | Verify that each SERCOS drive is assigned a unique node address. |
| E54 | DriveHardFault(lfbk HW fault) | Current feedback hardware fault detected. | Replace the module. |
| E55 | OverSpeedFault | The velocity error limit has been exceeded. | Motor has exceeded velocity error limit. | Check the cables for noise. |
| E60 | DriveHardFault(Unknown Axis) | Illegal ID bits detected. | Replace the module. |
| E61 | AuxFeedback Fault(Aux Fdbk AQB) | Auxiliary Encoder State Error. | The auxiliary encoder encountered an illegal transition. | - Use shielded cables with twisted pair wires. - Route the feedback away from potential noise sources. - Check the system grounds. - Replace the motor/encoder. |
| E62 | AuxFeedback Fault(Aux Fdbk Loss) | The feedback wiring is open, shorted, or missing. | Check the motor feedback cable connectors/wiring to the IAM/AM and motor. |
| E63 | AuxFeedbackNoise(Aux Fdbk Noise) | Noise on auxiliary feedback cable. | Recommended grounding, per installation instructions has not been followed. | - Verify grounding. - Route feedback cable away from noise sources. - Refer to System Design for Control of Electrical Noise Reference Manual(publication GMC-RM001). |
| E64 | AuxFeedbackNoise(Mtr Fdbk Noise) | Noise on motor feedback cable. | |
| E65 | No Fault Message(condition indicated by on-screen message)(Hookup Fault) | Hookup procedure failed. | Motor or feedback device malfunction. | - Check motor power/feedback wiring. - Refer to on-screen message for resolution. |
| E66 | No Fault Message(condition indicated by on-screen message)(Atune Flt) | Autotune procedure failed. | Motor or feedback device malfunction. | - Check motor power/feedback wiring. - Refer to on-screen message solution. - Perform Hookup in RSLogix 5000. - Consult RSLogix 5000 for help screen. |
| E67 | DriveHardFault(Task init) | Operating system failed. | Software initialization fault detected due to hardware failure. | - Cycle power. - If fault persists, replace module. |
| E68 | DriveHardFault(SCANport™Comm) | DPI communication failed. | The DPI device or cable is faulty. | Check DPI connections. |
| E69 | HardDriveFault(Objects init) | Non-volatile memory is corrupt due to control board hardware failure. | Load default parameters, save to non-volatile memory, and recycle power or reset the drive. |
| E70 | DriveHardFault(NV Mem Init) | Non-volatile memory is corrupt due to control board software error. | Load default parameters, save to non-volatile memory, and recycle power or reset the drive. |
| E71 | DriveHardFault(Memory Init) | RAM or flash memory validation failure. | - Cycle power. If fault persists, replace module. |
| E72 | DriveOvertemp Fault(Drive Overtemp) | Inverter thermal switch tripped. | The fan on the IAM or an AM failed. | Replace the failed module. |
| The cabinet ambient temperature is above rating. | Check the cabinet temperature. |
| The machine duty cycle requires an RMS current exceeding the continuous rating of the controller. | Change the command profile to reduce speed or increase time. |
| The airflow access to the Kinetix 6000 is limited or blocked. | Check airflow and re-route cables away from the Kinetix 6000. |
| E73 | Communicate(Backplane Comm) | Power rail CAN communications failed. | - Check module for proper mount. |
| Power rail connection shorted or open. | - Check power rail and module for foreign objects. | |
| E74 | DriveOvercurrentFault(BusOverCurrent) | DC link current exceeds rating. | Motor or transmission malfunction. | - Check for proper motor sizing. - Check/replace transmission device. - Check/replace motor. |
| IAM not properly sized. | - Check for proper IAM sizing. - Install larger kW rated IAM. |
| E75 | DriveOvervoltage Fault(Shunt Time Out) | The IAM, AM or SM has exceeded its shunt resistor continuous rating. | - Use a properly sized shunt or modify duty cycle of the application. - System uses internal shunt and requires external shunt for additional capacity. |
| E76 | DriveHardFault(CAN Init) | DPI hardware initialization fault detected. | Control board hardware failure. | - Reset system. - If fault persists, replace system module. |
| E77 | DriveHardFault(Module Mismatch) | Either 230V AM is installed on power rail with 460V IAM, or 460V AM is installed on power rail with 230V IAM. | Replace mismatched module. |
| E78 | DriveHardFault(SERCOS Init) | Control hardware fault detected. | - Cycle power. - If fault persists, replace module. |
| E79 | DriveOvervoltageFault(Shunt Module Flt) | SM Temperature Fault LED status is Steady Red | Refer to Temperature Fault LED |
| SM Shunt Fault LED status is Steady Red | Refer to Shunt Fault LED |
| Module missing from power rail. | - Install missing module on power rail. - Fill empty slot with slot filler module. | |
| E80 | DriveHardFault(CPLD Flt) | Control hardware fault detected. | Replace module. |
| E81 | DriveHardFault(Common Bus Flt) | Follower IAM detected AC input power being applied. | Remove AC input power connections from Follower IAM. |
| E90 | DriveHardFault(Pre-charge Timeout Flt) | Pre-charge resistor power exceeds the resistor rating. | Allow the resistor to cool. |
| All others | RESERVED | | | Call your local Rockwell Automation representative. |
IAM/AM LED - Troubleshoot
| Equipment Status | Program Step |
Drive Status LED
Use the table below for troubleshooting the Drive Status LED on your Kinetix 6000 IAM (2094-xCxx-Mxx) or AM (2094 xMxx)| If the Drive Status LED is: | Status is: | Potential Cause is: | Possible Resolution is: |
| Off | Normal, no faults. | N/A. | N/A. |
| Steady Red | Drive faulted. | Seven-segment LED displays error code. | Refer to the section Error Codes and continue troubleshooting. |
Comm Status LED
Use the table below for troubleshooting the Comm Status LED on your Kinetix 6000 IAM (2094-xCxx-Mxx) or AM (2094-xMxx).| If the Comm Status LED is: | Status is: | Potential Cause is: | Possible Resolution is: |
| Steady Green | Communication ready. | No faults or failures. | N/A. |
| Flashing Green | Establishing communication | System is still in the process of establishing SERCOS communication. | Wait for steady green LED status. |
| Node address setting on the drive module does not match SERCOS controller configuration. | Verify proper node switch setting. |
| Off | No communication | Loose fibre optic connection. | Verify proper fibre optic cable connection. |
| Broken fibre optic cable. | Replace fibre optic cable. |
| Receive fibre optic cable connected to SERCOS transmit connector and vice versa. | Check proper SERCOS fibre optic cable connections. |
Bus Status LED
Use the table below for troubleshooting the Comm Status LED on your Kinetix 6000 IAM (2094-xCxx-Mxx) or AM (2094-xMxx).| If the Bus Status LED is: | Status is: | Potential Cause is: |
| Steady Green | Bus power is present, axis enabled.No faults or failures. | Normal when:24V is applied to Hardware Enable Input (IOD-2).orMSO instruction is commanded in RSLogix 5000 software. |
| Flashing Green | Bus power is present, axis enabled.No faults or failures. | Normal when:24V is not applied to Hardware Enable Input (IOD-2).orMSO instruction is not commanded in RSLogix 5000 software. |
| Off | Bus power not present. | Normal when bus power is not applied.Fault exists, see Servo System Troubleshooting on page Servo System Troubleshooting. |
Sercos Card - Troubleshoot
| Equipment Status | Program Step |
The module provides three LED indicators to show the state of the system. The LED are located on the bezel of the SERCOS module. The OK LED, indicates the present health of the module and the communication status. The Sercos ring LED displays the status of the Sercos network. The Sercos communication LED displays the status of the Sercos communication phases. The Sercos communication LED is for informational purposes only.During power up, the module completes a self test that includes an indicator test. All LED go red for one second, green for one second, and off for one second.
- Sercos communication LED
- Sercos ring LED
- OK LED
Sercos Communication LED
| If the Sercos communication LED is: | Then the module status is: |
| Solid Orange | In Phase -1: Autobaud detection in progress. |
| Off | In Phase 0: looking for a closed ring. |
| Flashing Red | In Phase 1: looking for active nodes. |
| Alternating Red/Green | In Phase 2: configuring nodes for communication. |
| Flashing Green | In Phase 3: configuring device specific parameters |
| Solid Green | In Phase 4: configured and active. |
OK LED
| If the OK LED is: | Then the module status is: | Take this action: |
| Off | The module is not operating. | Apply chassis power.Verify the module is completely inserted into the chassis and backplane. |
| Flashing Green | The module has passed internal diagnostics, but has not established active communications. | None, if the module is not configured. |
| Steady Green | Data is being exchanged.The module is in the normal operating state. | None. The module is ready for action. |
| Flashing Red | A major recoverable failure has occurred.An NVS update is in progress. | If an NVS update is in progress, complete the NVS update.If an NVS update is not in progress: Reboot |
| Solid Red | A potential nonrecoverable fault has occurred. | Reboot the module.If the solid red persists,replace the module. |
Sercos Ring LED
| If the Sercos ring LED is: | Then the ring status is: | Take this action: |
| Solid Green | The ring, drive, and axes are configured and are actively communicating through to the nodes on the ring. | None |
| Flashing Red | The module has detected a setup or configuration fault with the ring. | Check your system setup and configuration as follows:- Ensure drive and axes addresses are correct.- Remove excess axes from ring.- Make sure application program has selected the proper Ring Cycle Period and Baud Rate. |
| Solid Red | The module has detected a hardware or installation fault with the ring. | Check your system hardware and installation as follows:- Make sure all cables are properly installed.- Make sure cable is of the correct type and length.- Make sure application program has configured the ring transmit level of the module to High when using specified cables.- Make sure the transmit levels of the drive are set appropriately.- Inspect cables for degradation.- Inspect drives for any faults and correct them. |
| Off | The module has detected no ring data on its receiver or has not successfully completed phase 2. | Check your system and installation as follows:- Make sure all cables are properly installed- Inspect cable for degradation and breakage.- Inspect drives for faults. |
| Flashing Green | The ring, drive, or axes are not configured but, at least one has been identified. | Not a problem if the system has not been configured. If you are having trouble configuring the ring, drive, and axes:- Make sure that the application program is setup properly for the equipment in use. |
Sercos - Troubleshoot
| Equipment Status | Power must be turn OFF.
|
| Consumables | Cable ties |
Machines that are equipped with Kinetix 6000 can sometimes have sporadic drive restarts or similar faults that are related to lost SERCOS communication.Servomotors can cause the SERCOS ring drop fault if the shielding is not correctly clamped to the servo drive shield connector. This is valid mostly for servo drives with the old type of clamping.
Old clamp

New clamp
If a fault is connected to SERCOS, follow the instructions:- Check the connectors on all servomotor cables, especially grounding and shield connections.
- If hardware fault is suspected, exchange the hardware with a similar hardware in the machine. If the fault is transferred, replace the hardware. If the fault remains in the same place, change back again.
- Check all terminals that are related to the servo drive supply and safety. Check for loose wire and corrosion.
- Check all fibre optic cables. If there is any suspected damage or discontinuous bend on the radius, replace the cable. If the cable connectors are contaminated inside, clean or replace them.
- Rearrange the shield clamping on top of the drives even if it looks correct. See the illustration below. Make sure that there is contact between the cables.

Correct

Incorrect

Incorrect
- Brake shield
- Motor power
- Check the grounding of the motor feedback cable shield.Note: The Mechanical stress fastening can be turned upside down to get better connection to the shielding.

- Mechanical stress fastening
- Check the diodes of the PLC SERCOS card and drives. If any suspected fault or unique behaviour, photograph or record the behaviour.
- For all drives, switch optical power to low intensity by setting to OFF.
- In the PLC software, select .
- In the , change
Transmit Power to . - Repeat item Reference to Reference for .

- Optical power
- LSBBaud rate
- MSBBaud rate

- SERCOS_Ring1
- SERCOS_Ring2

- Module Properties
- Low
- Check the assembling of the servo drive. If the mounting screws are tightened and there is play, bend the upper hook on the drive to tighten it against the backplane. If necessary, replace the drive.
- Check the cable route, local adaptations, and the hardware changes on the drive systems (for example extra sensors or connections to drives). Document and try to assess the EMC compliance. If there is uncertainties, contact EMC specialists.
- Check the servomotor grounding and connectors. If there are abnormalities, repair or replace the connectors. Bayonet connectors can sometimes have mechanical play, use cable ties to reduce unwanted play.
- Measure the power supply to the machine, voltage fluctuations greater than 10% of nominal is not recommended.
- Make sure that the firmware on the PLC SERCOS communication card is revision 15.37 or higher.
- Check the firmware. The recommended firmware is ≥1.125 and <1.132.Note: Drives with firmware higher than 1.132, cannot be degraded again.
- Exchange the SERCOS cards in the main electrical cabinet. If the problem transfers to the other SERCOS ring, replace the PLCSERCOScard.
Further Faultfinding Troubleshoot
- Replace all fibre optic cables.
- Dismantle all drives. Check the backplane and the drive connectors for damage or contamination. Take a picture of the nameplate of the backplane and reassemble.
Functional Description
Sercos is a fibre-optic communication standard used for motion control. There are two Sercos cards in the TT/3 machine, and which control the five Servo rack (six for variant XH with IC).
- Sercos card A01K0032
- Sercos card A01K0033
- Servo rack
Sercos Card - Change
| Equipment Status | Power must be turn OFF.
|
Hazardous voltage.The main power supply disconnector must be switched off and secured with a lock before starting any work inside the electrical cabinet.Can shock or burn.
- Mark the Receive connector, Rx and the Transmit connector, Tx. Disconnect the connectors from the Sercos card.

- Sercos card
- Receive connector, Rx
- Transmit connector, Tx
- Push in and hold the top and bottom Locking tab on the Sercos card.
- Pull the card out of the Chassis.

- Sercos card
- Locking tab
- Chassis
- Align the Card circuit board with the top and bottom Chassis guide.

- Chassis guide
- Card circuit board
- Push evenly and firmly to seat the card in the chassis. It is seated when the top and bottom Locking tab have snapped into place.

- Locking tab
- Connect the Receive connector, Rx and the Transmit connector, Tx to the Sercos card.

- Sercos card
- Receive connector, Rx
- Transmit connector, Tx
Functional Description
The Servo drive are placed in the Servo rack and are provided with power from the Integrated Axis Module IAM.
- Servo drive
- Servo rack
- IAM
Servo Drive - Set Baud Rate
| Equipment Status | Power must be turn OFF.
|
| Special Equipment | Voltmeter |
Set the DIP switches according to the table and illustration below.
Integrated Axis ModuleAxis Module
Servo Drive - Remove
| Equipment Status | Power must be turn OFF.
|
| Special Equipment | Voltmeter |
Residual voltage.Make sure that all control and input power have been removed from the system. Wait five minutes for the DC bus to discharge completely before starting any work.Can shock or burn.
Note: Do not move the servo drive for the cam module T21T0016, marked 250% peak, to any other place.- Mark all connectors from the servo drive and then remove the connectors.
- Use a Screwdriver to remove the Motor cable from cable shield Clamp.

- Motor cable
- Clamp
- Screwdriver
- Loosen the mounting screw (bottom centre of each servo drive).
- Grasp top and bottom of the Servo drive with both hands and gently pull the servo drive away from the connectors enough to clear the Guide pin (the servo drive will pivot on top bracket). Lift the bracket out of the Power rail slot and remove servo drive from the power rail.

- Guide pin
- Power rail
- Servo drive
- If the servo drive that is replaced is an Integrated Axis Module (IAM), record the Node address and set the baud rate switches correct.

- Node address
Power Rail - Change
| Equipment Status | Power must be turn OFF.
|
| Special Equipment | Voltmeter |
Hazardous voltage.Disconnect all power from the servo power rail.Can shock, burn, or cause death.
- Disconnect all power from the power rail servo drives and remove all servo drives from the Power rail.
- Disconnect the Braided ground strap from the Grounding stud.
- Loosen the mounting bolts.
- Lift the power rail up and off the mounting bolts.

- Braided ground strap
- Grounding stud
- Power rail
Risk of damage to the equipment.Do not remove the protective boots until the servo drive for each slot is ready for mounting.The power rail can be damaged.
Align the replacement Power rail over the existing mounting bolts.- Tighten the mounting bolts.
- Connect the Braided ground strap to the power rail Grounding stud.

- Braided ground strap
- Grounding stud
- Power rail
Servo Drive - Fit
| Equipment Status | Power must be turn OFF.
|
| Special Equipment | Voltmeter Torque wrench |
Hazardous voltage.Disconnect all power from the power rail servo.Can shock, burn, or cause death.
If there are any protective boots on the Power rail connector, remove them.- Hang the Mounting bracket from the Slot on the power rail.
Risk of damage to the equipment.The power rail must be in vertical orientation before replacing servo drives or pins may not seat properly.The power rail can be damaged.
Align the Guide pin on the power rail with the guide pin holes in the back of the Servo drive.Note: The IAM has two power rail connectors and guide pins, all other servo drives have only one connector and one guide pin.
- Guide pin
- Power rail
- Servo drive
- Slot
- Mounting bracket
- Tighten the Mounting screw to a torque of 2.26 Nm.
- If the servo drive that is replaced is an Integrated Axis Module (IAM), set the Node address and set the baud rate switch according to the record made in Servo Drive - Set Baud Rate on page Servo Drive - Set Baud Rate.
- Reconnect the servo drive connectors.
- Re-apply power to the system.
- Verify that the system is operating properly.Note: Tuning or setup procedures are not necessary to perform since the parameters of the servo drive reside in the RSLogix 5000 software.Note: When replacing the servo drive for the cam module (T21T0016) make settings according to on page and mark the new drive with the text:Note: 250% peak. Read MM before moving/replacing.

- Mounting screw
- Node address
Servo Drive - Peak Enhancement
| Equipment Status | Program Step |
| Special Equipment | Human Interface Module for PowerFlex 7-Class, TP no. 90600-3019, with firmware V5.003 Cable, TP no. 90600-3020 |
Note: Valid for servo drives series B drive with firmware 1.111 or higher.Note: Only valid for the servo drive for the cam module (T21T0016, marked 250% peak).Connect to the Servo Drive
- Disconnect the sercos ring by removing one Optical conductor from the Servo drive.
- Connect the Human Interface Module (HIM) to the Servo drive.

- Optical conductor
- Servo drive
- HIM)Human Interface Module (
- Press Esc to ignore the sercos ring fault.
- Wait until the display shows
Not selected. - Press Enter.

- Esc
- Enter
Find and change parameter
- Press Alt and then +/- to select Param #.
- Enter the value 507.
- Press Enter twice.
- Press the Up arrow, the value changes from 0 to 1, and the information changes from 150% to 250%.
- Press Enter.
- Press Esc.

- Esc
- Enter
- Alt
- +/-
- Up arrow
Store the Changed Parameters to the Memory in the Servo Drive
- Press the DOWN ARROW until display shows
Memory Storage. - Press Enter and then press the DOWN ARROW until the display shows
EEPROM. - Press Enter.
- Press Enter to store the parameters.
- Press Esc.

- Esc
- Enter
- DOWN ARROW
Disconnect from the Servo Drive
- PressAlt and then Enter to access the remove function.
- Press Enter.
- Disconnect the Human Interface Module (HIM) from the Servo drive.
- Connect the Optical conductor to the Servo drive.

- Optical conductor
- Servo drive
- Human Interface Module (HIM)
- Enter
- Alt
Functional Description
The emergency stop buttons and stop cords, are connected by two channels, one constant +24 VDC and one pulse shaped voltage from the safety PLC (Pluto). Both channels have to be opened and closed at the same time to allow the system to reset, however it is enough that one channel is open to make the system trip. The Adam/Eva safety switches for the doors are operating with one channel, the puls shaped voltage form the safety PLC. The system monitors the contactors that will be turned off when the system trip. If a feedback circuit is not OK after the system has tripped it is not possible to reset.For more information about door guards and emergency stop buttons/cord see Covers and Doors and Emergency Stop Device.Pluto - Set Address after Replacing or Changing an ID-FIX
| Equipment Status | Program Step step zero |
| Special Equipment | Computer with Pluto Manager 1.31 installed Encrypted file (spe) Hexadecimal file (hps) Programming cable for Pluto Safety PLC, TP no. 90459-6033 |
Personnel Requirements.Only authorised and skilled personnel are allowed to make settings in the safety system.Changing the pluto settings can affect the machine in unexpected ways.
If one of the ID-fix has been replaced the address has to be set. There is a function for programmable identifier circuits IDFIX-RW.- Start Pluto Manager.
- Connect the programming cable between the computer and the Pluto.
- From to the
Tools menu, select Write IDFIX. 
- Write IDFIX
- Type the ID number in the ID number field. The ID numbers are listed in the table. Click Write ID circuit.
- The system can also suggest a number by clicking Suggest unique ID. Do not use this feature.
| ID number |
| Unit | Machine 1 | Machine 2 | TTCU |
| F03K0014 | 0300F03F0014 | 2300F03F0014 | |
| F03K0016 | 0400F03F0016 | 2400F03F0016 | |
| F03K0024 (in ASU) | 0500F03F0024 | 2500F03F0024 | |
| F73A0200 | | | 2700F73F0200 |
Note: The ID number for the Pluto units is different depending on if the machine is the first or second machine connected to the TTCU. The first machine always have ID numbers 3 and 4 in the main electrical cabinet and 5 in the ASU electrical cabinet. The second machine has ID numbers 23,24, and 25. 
- ID number field
- Erase protect ID check box
- Write ID circuit
- Suggest unique ID
Pluto - Change Baud Rate, Error Code Er26
| Equipment Status | Program Step |
| Special Equipment | Computer with Pluto Manager 1.31 installed Encrypted file (spe) Hexadecimal file (hps) Programming cable for Pluto Safety PLC, TP no. 90459-6033 |
Personnel Requirements.Only authorised and skilled personnel are allowed to make settings in the safety system.Changing the pluto settings can affect the machine in unexpected ways.
A Pluto unit cannot change baud rate during operation. If a unit is loaded with a program with new baud rate, it will continue with the old baud rate and indicate error code Er26. The error code Er26 indicates that a unit is running with another baud rate than it is programmed for. Change baud rate by rebooting the Pluto PLC:- Reboot by Power Off/On, or
- via Pluto Manager by selecting the
Tools menu and then selecting Reset all Plutos. 
- Reset all Plutos
If a Pluto that is empty of program (error code Er20) is loaded with a program it will also indicate error code Er26 and has to be rebooted in order to start with the programmed baud rate.
Pluto - Replace in an Existing Application
| Equipment Status | Program Step |
| Special Equipment | Computer with Pluto Manager 1.31 installed Encrypted file (spe) Hexadecimal file (hps) Programming cable for Pluto Safety PLC, TP no. 90459-6033 |
Personnel Requirements.Only authorised and skilled personnel are allowed to make settings in the safety system.Changing the pluto settings can affect the machine in unexpected ways.
- Remove the Terminal block by using a screwdriver in Slot.
- Change the Pluto unit.
- Assemble in revers order.

- Terminal block
- Slot
- Pluto unit
When a new unit is connected to the bus, the new Pluto unit will show error code Er20 or Er27, install PLC program accordingly.
Error Code Er20:
The new Pluto can be programmed by using self programming without a PC.- Push the K button in the in the Pluto front panel for two seconds.
- The display flashes Lo, which indicates that the system is ready for self programming.
- Push the K button one more time.
- The program load is started, this is indicated by a steady Lo on the display.

- K button
Error Code Er27:
The new Pluto can be loaded with a program through a new download from the PC, see Pluto - Download Program from a PC on page Pluto - Download Program from a PC.Pluto - Download Program from a PC
| Equipment Status | Program Step |
| Special Equipment | Computer with Pluto Manager 1.31.installed Encrypted file (spe) Hexadecimal file (hps) Programming cable for Pluto Safety PLC, TP no. 90459-6033 |
Personnel Requirements.Only authorised and skilled personnel are allowed to make settings in the safety system.Changing the pluto settings can affect the machine in unexpected ways.
Note: The program must be compiled before it can be downloaded. A fault message is shown if the program is not compiled.- Start Pluto Manager.
- Connect the programming cable between the computer and the Pluto.
- Open the program file and select the Pluto.
- Click Download in the tool bar.

- Download
- If the unit is not loaded with a password, a dialogue box appears asking for a new password.
- Type the password abc80 in the Password field.
- Confirm the password in the Confirm Password field and click OK.

- Password field
- Confirm Password field
- OK
- If the unit is loaded with a password, a dialogue box appears asking for the password.
- Type the password abc80 in the Password field.
- Click OK.
- If the fault message Couldn’t establish connection.. appears there is no connection at all.
- If the fault message Connection time out.. appears the communication is interrupted.
If any of these two fault messages appears check that the communication cable is correctly connected.
- Password field
- OK
- If everything is OK a dialogue box appears saying that the file is downloaded and asking whether the execution of the program should be started or not.

The illustration shows an example.
- Click Yes.
- IfNo is selected it is possible to start execution by clickingOnline and then Start.Note: A warning is given if the program project is for several Pluto stations and all stations are not connected to the bus.

The illustration shows an example.
- Yes
- No
- Online
- Start
Pluto - Safety System Alarm on the TPOP
| Equipment Status | |
| Special Equipment | Computer with Pluto Manager 1.31 installed Encrypted file (spe) Hexadecimal file (hps) Programming cable for Pluto Safety PLC, TP no. 90459-6033 |
The TTCU alarm symbol indicates that the TTCU Pluto system has not been reset. The symbol appears when the emergency stop button is activated or if there is an error message on the Pluto in the TTCU. The symbol only appears if a cleaning program is selected on the TT/3 machine, if not the TTCU warning lamp is red but there is no alarm on the TT/3 TPOP.
- TTCU alarm symbol
Reset Pulse from Relay to the Pluto System
In order to restore the safety system after an emergency stop, an open door or a safety system error, UE or Er-code, the Pluto system need a 24 V on and off reset pulse to F03K0016:IQ14. The reset pulse comes from relay F03K0009. This is activated when restoring the emergency stop line or when acknowledging a door guard alarm on the TPOP.If a Pluto module displays an UE-code (safety system error) due to a channel fault or a feedback error, the faulted circuit must be corrected first, to be able to remove the UE-code by a reset pulse.Reset Relay F03K0009
If the PLC does not activate the reset relay it can be made manually. Pull down the blue Cover shield on relay F03K0009 with a small screwdriver and push the Yellow button underneath for a short while.
- Cover shield
- Yellow button
EDEN, Adam/Eva Sensors
Eden, Adam/Eva is a non-contact sensor with dynamic signal transmission (10 V pulse).Several Eden connectors can be connected to the same safety circuit (Tina 4 A or Tina 8 A) and be monitored dynamically by the Pluto safety PLC.An info signal (24 V) from each sensor is used in the PLC machine program for monitoring the individual doors on the machine.LED Indicator on Adam Sensor
For a stabile signal the distance between Adam and Eva sensors outer cover must be with accordance to the Procedure Safety Switch - Set on page Safety Switch - Set.| Adam LED | Eva |
| Green | Eva sensor within range (door closed). Safety circuit closed up to this point |
| Flashing equal green/red | Eva sensor within range (door closed). Safety circuit open on other position |
| Red | Eva sensor out of range, safety circuit open (door open) |
| Green with fast flashing red | Eva sensor is near to its maximum sensing distance (door closed but sensors badly adjusted) |
Tina 4A and Tina 8A Connector Blocks
Door guards belonging to the same safety circuit are connected to the connector blocks.Unused connections must be filled out with Tina 1A connectors to obtain the safety circuit signal through the block.An info signal (24V) from each Adam/Eva sensor is distributed from the connector block to a PLC input and is used in the PLC machine program for monitoring the doors individually on the machine.| Carton Section | Package Section |
| Tina 4 A | Tina 8A | Tina 8A |
| Lower Doors S1 | Upper Doors incl. CAU S1 | All Doors S1 |
| Lower Doors S2 | Upper Doors incl. CAU S2 | All Doors S2 |
Tina 1A Connector
The Tina 1A is working as jumpers for the dynamic signal (10V pulse) in the safety circuit and is needed on the unused positions on Tina 8A connector blocks.Note: A Tina 1A connector can not be used as a substitute for an Adam/Eva door guard since the info signal (24V) from the Adam /Eva sensor to the machine PLC is missing.LED Indication on Tina 1A Connectors
| Green | Safety circuit closed |
| Green/Red | Safety circuit open |
Termination resistors on the Pluto Bus
A 120 Ohm resistor must be connected between CL and CH terminals on the first and last Pluto module in the Bus.If you have only one machine connected to a TTCU it means that the Pluto module in the ASU and the TTCU shall have a resistor. Resistors on the other Pluto modules must be removed for correct impedance on the Bus.If you have two machines connected to one TTCU it means that the Pluto modules in ASU on both machines shall have a resistor. Resistors on the other Pluto modules must be removed for correct impedance on the Bus.ID-Fix RW
This is a programmable identifier to give the Pluto module an address. The ID-Fix address selects which part in the program to read.Communication Cable between PC and Pluto Module
Pluto - Description of Inputs, Outputs, and LEDs
For more detailed information on connections, look in the Circuit Diagram in the Electrical Manual.Pluto 27, F73A0200 in TTCU
The table shows the LED lit when the TTCU is not used by any of the TT/3 machines.| LED | Input / Output | Normal state |
| I0 | E-stop | Lit |
| I1 | E-stop | Lit |
| I2 | External E-stop | Lit |
| I3 | External E-stop | Lit |
| I4 | Not used | Not lit |
| I5 | Not used | Not lit |
| I6 | Not used | Not lit |
| I7 | Feedback E-stop | Lit |
| IQ10 | Output A-pulse to safety circuits (Pulse 10V out) | Lit |
| IQ11 | Reset | Not lit |
| IQ12 | Not used | Not lit |
| IQ13 | Not used | Not lit |
| IQ14 | Machine 1 takes TTCU | Not lit |
| IQ15 | Machine 2 takes TTCU | Not lit |
| IQ16 | TTCU Machine 2 takes TTCU D-NET | Not lit |
| IQ17 | Error Message | Lit |
| 0L | E-stop | |
| Q0 | L21 | Not lit |
| 1L | Not used | |
| Q1 | Not used | Not lit |
| Q2 | Main contactor emergency stop (-24 V) | Not lit |
| Q3 | Not used (-24 V) | Not lit |
| ID | Identifier on the CAN bus | |
Comment on Inputs/Outputs on Pluto 27 (TTCU)
| I0, I1 | It is important that these two inputs, from Emergency Stops on the TTCU, activate or deactivate at the same time. Otherwise a two channel fault will occur and the UE code 01 is displayed on the Pluto.If UE code 00 is shown on the Pluto it means that one of the two channels is permanent missing. |
| I2, I3 | It is important that these two input, from External Emergency Stops to the TTCU, activate or deactivate at the same time. Otherwise a two channel fault will occur and the UE code 03 is displayed on the Pluto. Permanent jumpers are connected to terminals if no external emergency stop is connected. If UE code 02 is shown on the Pluto it means that one of the two channels is permanent missing. |
| I4, I5, I6 | Not used |
| I7 | This feedback signal goes through and monitors the contactors that should be off when an emergency stop has been activated (button pushed. I0, I1 or I2, I3 is off). If everything is correct (contactors are off) the Input will be on (LED lit). The safety system can then be restored when the reset signal to Pluto 27: IQ11 goes on and off again. If there is no signal to the I7 when an emergency stop has been activated the Pluto will show UE code 07 and the safety system can not be restored. |
| IQ10 | Dynamic output pulse +10V (A-Pulse) created in the Pluto system. |
| IQ11 | In order to restore the safety system in the TTCU after an emergency stop or safety system error (UE-code) the Pluto system need a 24V on and off pulse to this input. The reset pulse comes from relay F73K0202. This is activated from the reset button on the TTCU. If a Pluto module displays an UE-code (safety system error) due to a channel fault or a feedback error, the faulted circuit must be corrected first, to be able to remove the UE-code by a reset pulse. A reset pulse can also be made manually with a small screwdriver by pulling down the blue cover shield on relay F73K0202 and pushing the yellow button underneath for a short while. |
| IQ12, IQ13 | Not used |
| IQ14 | Info signal to PLC |
| IQ15 | Info signal to PLC |
| IQ16 | This output activates relays for switching to machine 2 (Recorder and DeviceNet communication). |
| IQ17 | This output is on (LED lit) when everything in the Pluto module in the TTCU is ok. If a fault occurs (shown by Er and a number in the display) or if a signal fail to come, for instance a missing “Two channel signal” or a feedback signal, (shown by UE and a number) the output goes off. |
| 0L | Supply terminal for relay output Q0. (Comes from a 24VDC line). |
| Q0 | Emergency stop controlled 24V for digital output supply and FESTO pneumatic valve supply. |
| 1L | Not used. |
| Q1 | Not used. |
| Q2 | Emergency stop controlled main contactor. Note: This output delivers -24V. This means that contactors connected to it must be connected in opposite polarity. (Machine L10 to + or A1 and Q2 to - or A2). |
| Q3 | Not used. Note: This Output delivers -24V. This means that expansion relays or contactors connected to it must be connected in opposite polarity. (Machine L10 to + or A1 and Q3 to - or A2). |
Pluto 3 and 23, F03K0014 in TT/3 Main Electrical Cabinet
The table shows the LED lit when all emergency stops are reset and all safety doors are closed and the machine is ready to step up.
Machine 1

Machine 2
| LED | Input/Output | Normal state |
| I0 | Input emergency stops on the machine (+24V) | Lit |
| I1 | Input emergency stops on the machine (Pulse 10V in) | Lit |
| I2 | Input external emergency stop (+24V) | Lit |
| I3 | Input external emergency stop (Pulse 10V in) | Lit |
| I4 | Input feedback from emergency stop (Pulse 10V in) | Not lit |
| I5 | Input feedback from UV-power S1 (Pulse 10V in) | Lit (UV off) |
| I6 | Input feedback from UV-power S2 (Pulse 10V in) | Lit (UV off) |
| I7 | Input feedback from Package Section common and servo drives (Pulse 10V in) | Not lit |
| IQ10 | Output A-pulse to safety circuit (pulse 10V out) | Lit |
| IQ11 | Input from Adam sensor on hygienic chamber cleaning hatch S1 (Pulse 10V in) | Lit (closed)Not lit (open) |
| IQ12 | Input Package Section Doors S1 (Pulse 10V in) | Lit |
| IQ13 | Input Package Section Doors S2 (Pulse 10V in) | Lit |
| IQ14 | Not used | Not lit |
| IQ15 | Input from PLC, Clean Hygienic Chamber S1 (+24V in) | Not lit |
| IQ16 | Input from PLC, Clean Hygienic Chamber S2 (+24V in) | Not lit |
| IQ17 | Output info to PLC, error message from Pluto module (+24V out) | Lit |
| 0L | 24Vsupply to relay output Q0 | |
| Q0 | Relay output to UV-power S1 | Lit |
| 1L | 24Vsupply to relay output Q1 | |
| Q1 | Relay output to UV-power S2 | Lit |
| Q2 | Opto Output (-24 V) to expansion unit for L31, L32. (Pack Sect 24V) | Lit |
| Q3 | Opto Output (-24 V) to expansion unit for L12. (Emergency stop OK 24V) | Lit |
Comment on Inputs/Outputs on Pluto 3 (23)
| I0, I1 | It is important that these two input, from emergency stops on the machine, activate or deactivate at the same time. Otherwise a two channel fault will occur and the UE code 01 is displayed on the Pluto.If UE code 00 is shown on the Pluto it means that one of the two channels is permanent missing. |
| I2, I3 | It is important that these two input, from external emergency stops to the machine, activate or deactivate at the same time. Otherwise a two channel fault will occur and the UE code 03 is displayed on the Pluto. Permanent jumpers are connected to terminals if no external emergency stop is connected.If UE code 02 is shown on the Pluto it means that one of the two channels is permanent missing. |
| I4 | This feedback signal goes through and monitors the contactors that should be off when an emergency stop has been activated (button pushed or a cord pulled. I0, I1 or I2, I3 is off). The signal also monitors the shut down of the filling servo rack #10 (safe off connections). If everything is correct (contactors and servo rack is off) the input will be on (LED lit). The safety system can then be restored when the reset signal to Pluto 4: IQ14 goes on and off again. After reset the I4 will be off due to the fact that contactors and servo rack activates when the safety system for emergency stop restores. If there is no signal to the I4 when an emergency stop has been activated the Pluto will show UE code 04 and the safety system can not be restored. |
| I5 | This feedback signal monitors the UV-lamp contactors off state for S1. If there is no signal to the I5 when a door on package section on side 1 has been opened the Pluto will show UE code 05 and the safety system can not be restored. |
| I6 | This feedback signal monitors the UV-lamp contactors off state for S2.If there is no signal to the I6when a door on package section on side 2 has been opened the Pluto will show UE code 06 and the safety system can not be restored. |
| I7 | This feedback signal goes through and monitors the contactors that should be off when a door guard stop from package section has been activated (IQ12 or IQ13 is off). The signal also monitors the shut down of the package section servo rack #20 and #30 (safe off connections). If everything is correct (contactors and servo rack is off) the Input will be on (LED lit). The safety system can then be restored when the reset signal to Pluto 4: IQ14 goes on and off again.After reset the I7 will be off due to the fact that contactors and servo rack activates when the safety system for package section door guard stop restores.If there is no signal to the I7 when a package section door guard stop has been activated the Pluto will show UE code 07 and the safety system can not be restored. |
| IQ10 | Dynamic output pulse +10V (A-Pulse) created in the Pluto system. |
| IQ11 | This input is on (LED lit) when the hatch between carton and package section on S1 is closed. If it's closed the machine can make an intermediate clean from TTCU while still running production on the other side of the machine. |
| IQ12 | This input is on (LED lit) when the safety circuit for pack sect S1 is ok. All doors (5) are closed and no Tina 1 connectors missing on the Tina 8 block. |
| IQ13 | This input is on (LED lit) when the safety circuit for pack sect S2 is ok. All doors (5) are closed and no Tina 1 connectors missing on the Tina 8 block. |
| IQ15, IQ16 | Info signals from PLC |
| IQ17 | This output is on (LED lit) when everything in the Pluto module is ok. If a fault occurs (shown by Er and a number in the display) or if a signal fail to come, for instance a missing “Two channel signal” or a feedback signal, (shown by UE and a number) the output goes off. |
| 0L | Supply terminal for relay output Q0. (Comes from a PLC output). |
| Q0 | When open a door on package section side 1 (IQ12 is off) this output goes off. |
| 1L | Supply terminal for relay output Q1. (Comes from a PLC output). |
| Q1 | When open a door on package section side 2 (IQ13 is off) this output goes off. |
| Q2 | When opening any door on package section (IQ12 or IQ13 is off) this output goes off.Note: This output delivers -24V. This means that expansion relays or contactors connected to it must be connected in opposite polarity. (Machine L10 to + or A1 and Q2 to - or A2). |
| Q3 | When activating (external or internal) emergency stop (I0, I1 is off or I2, I3 is off) this output goes off.Note: This output delivers -24V. This means that expansion relays or contactors connected to it must be connected in opposite polarity. (Machine L10 to + or A1 and Q3 to - or A2). |
Pluto 4 or 24, F03K0016 in TT/3 Main Electrical Cabinet
The table shows the LED lit when all emergency stops are reset and all safety doors are closed and the machine is ready to step up.
Machine 1

Machine 2
| LED | Input/Output | Normal state |
| I0 | Input Service switch (+24V) | Not lit |
| I1 | Input Service switch (Pulse 10V in) | Not lit |
| I2 | Input Carton Section upper door guards S1 (Pulse 10V in) | Lit |
| I3 | Input Carton Section upper door guards S2 (Pulse 10V in) | Lit |
| I4 | Not used | Not lit |
| I5 | Input feedback from Pluto pulse (Pulse 10V in) | Lit |
| I6 | Input feedback from Carton Section common and servo drives (Pulse 10V in) | Not lit |
| I7 | Input feedback from hydraulic pump (Pulse 10V in) | Not lit |
| IQ10 | Output A-pulse to safety circuit (pulse 10V out) | Lit |
| IQ11 | Input from Adam sensor on hygienic chamber cleaning hatch S2 (Pulse 10V in) | Lit (closed) Not lit (open) |
| IQ12 | Input Carton Section lower door guards S1 (Pulse 10V in) | Lit |
| IQ13 | Input Carton Section lower door guards S2 (Pulse 10V in) | Lit |
| IQ14 | Input from reset relay (+24V in) | Not lit |
| IQ15 | Output info to PLC, TTCU cleaning other TT3 (+24V out) | Not lit |
| IQ16 | Output info to PLC, TTCU safety ready (+24V out) | Lit |
| IQ17 | Output info to PLC, error message from Pluto module (+24V out) | Lit |
| 0L | 24Vsupply to relay output Q0 | |
| Q0 | Relay output Not used | Not lit |
| 1L | 24Vsupply to relay output Q1 | |
| Q1 | Relay output for power supply to cleaning hatches Carton/Package | Lit |
| Q2 | Opto Output (-24 V) to expansion unit for L21, L22. (Cart Sect 24V) | Lit |
| Q3 | Opto Output (-24 V) to expansion unit for Hydraulic pump | Lit |
Comment on Inputs/Outputs on Pluto 4 (24)
| I0, I1 | It is important that these two input, from service switch in the electrical cabinet, activate or deactivate at the same time. Otherwise a two channel fault will occur and the UE code 01 is displayed on the Pluto.If UE code 00 is shown on the Pluto it means that one of the two channels is permanent missing. |
| I2 | This input is on (LED lit) when the safety circuit for carton sect upper S1 is ok. All doors (4 or 5 if CAU) are closed and no Tina 1 connectors missing on the Tina 8 block. |
| I3 | This input is on (LED lit) when the safety circuit for carton sect upper S2 is ok. All doors (4 or 5 if CAU) are closed and no Tina 1 connectors missing on the Tina 8 block. |
| I4, I5 | Not used |
| I6 | This feedback signal goes through and monitors the contactors that should be off when a door guard stop from carton section has been activated (I2, I3 or IQ12, IQ13 is off). The signal also monitors the shut down of the carton section servo rack #40, #50, #60 (safe off connections). If everything is correct (contactors and servo rack is off) the input will be on (LED lit). The safety system can then be restored when the reset signal to Pluto 4: IQ14 goes on and off again. After reset the I6 will be off due to the fact that contactors and servo rack activates when the safety system for carton section door guard stop restores.If there is no signal to the I6 when a carton section door guard stop has been activated the Pluto will show UE code 06 and the safety system can not be restored. |
| I7 | This feedback signal goes through and monitors if the contactors for hydraulic pump is off when a door guard stop from carton section has been activated (I2, I3 or IQ12, IQ13 is off). If everything is correct the input will be on (LED lit). The safety system can then be restored when the reset signal to Pluto 4: IQ14 goes on and off again. After reset the I7 may be off due to the fact that contactors activates when the safety system for carton section door guard stop restores.If there is no signal to the I7 when a carton section door guard stop has been activated the Pluto will show UE code 07 and the safety system can not be restored. |
| IQ10 | Dynamic output pulse +10V (A-Pulse) created in the Pluto system. |
| IQ11 | This input is on (LED lit) when the hatch between carton and package section on S2 is closed. If it is closed the machine can make an intermediate clean from TTCU while still running production on the other side of the machine. |
| IQ12 | This input is on (LED lit) when the safety circuit for carton sect lower S1 is ok. All doors are closed. |
| IQ13 | This input is on (LED lit) when the safety circuit for carton sect lower S2 is ok. All doors are closed. |
| IQ14 | In order to restore the safety system after an emergency stop, an open door or a safety system error (UE-code) the Pluto system need a 24V on and off pulse to this input. The reset pulse comes from relay F03K0009. This is activated from the TPOP when restoring an emergency stop button or an emergency stop cord or when acknowledging a door guard alarm.If a Pluto module displays an UE-code (safety system error) due to a channel fault or a feedback error, the faulted circuit must be corrected first, to be able to remove the UE-code by a reset pulse.A reset pulse can also be made manually with a small screwdriver by pulling down the blue cover shield on relay F03K0009 and pushing the yellow button underneath for a short while. |
| IQ15, IQ16 | Info signals to PLC |
| IQ17 | This output is on (LED lit) when everything in the Pluto module is ok.If a fault occurs (shown by Er and a number in the display) or if a signal fail to come, for instance a feedback signal, (shown by UE and a number) the output goes off. |
| 0L, Q0 | Not used |
| 1L | Supply terminal for relay output Q1. (Comes from L11). |
| Q1 | This output supply a PLC output module controlling the carton/package hatches and is only activated when all doors on carton and package section are closed. |
| Q2 | When opening any door on carton section (I2, I3, IQ12 or IQ13 is off) this output goes off.Note: This output delivers -24V. This means that expansion relays or contactors connected to it must be connected in opposite polarity. (Machine L10 to + or A1 and Q2 to - or A2). |
| Q3 | This output goes off if:Service switch is in off position (I0, I1 off) and any door on carton section is opened.Service switch is activated (I0, I1 lit) and emergency stop is activated (I0, I1 is off or I2, I3 is off on Pluto 3).Note: This output delivers -24V. This means that expansion relays or contactors connected to it must be connected in opposite polarity. (Machine L10 to + or A1 and Q3 to - or A2). |
Pluto 5 or 25, F03K0024 in TT/3 Electrical Cabinet in ASU
The table shows the LED lit when all emergency stops are reset and all safety doors are closed and the machine is ready to step up.
Machine 1

Machine 2
| LED | Input/Output | Normal state |
| I0 | Input SA-Oven door S1 (Pulse 10V in) | Lit |
| I1 | Input SA-Oven door S2 (Pulse 10V in) | Lit |
| I2 | Input Strip magazine door S1 (Pulse 10V in) | Lit |
| I3 | Input Strip magazine door S2 (Pulse 10V in) | Lit |
| I4 | Not used | Not lit |
| I5 | Not used | Not lit |
| I6 | Input feedback from Expansion relay Door guards ASU S1 (Pulse 10V in) | Not lit |
| I7 | Input feedback from Expansion relay Door guards ASU S2 (Pulse 10V in) | Not lit |
| IQ10 | Output A-pulse to safety circuit (pulse 10V out) | Lit |
| IQ11 | Input from Adam sensors from rear cover and door on ASU S1 (Pulse 10V in) | Lit |
| IQ12 | Input/Output Reset button and lamp S1 (Pulse 10V in/+24V out) | Not lit |
| IQ13 | Input from Adam sensors from rear cover and door on ASU S2 (Pulse 10V in) | Lit |
| IQ14 | Input/Output Reset button and lamp S2 (Pulse 10V in/+24V out) | Not lit |
| IQ15 | Not used | Not lit |
| IQ16 | Not used | Not lit |
| IQ17 | Output info to PLC, error message from Pluto module (+24V out) | Lit |
| 0L | 24Vsupply to relay output Q0 | |
| Q0 | Relay output for Strip Splice Head cylinder S1 | Lit |
| 1L | 24Vsupply to relay output Q1 | |
| Q1 | Relay output for Strip Splice Head cylinder S2 | Lit |
| Q2 | Opto Output (-24 V) to expansion unit for rear cover and door on ASU S1 | Lit |
| Q3 | Opto Output (-24 V) to expansion unit for rear cover and door on ASU S2 | Lit |
Comment on Inputs/Outputs on Pluto 5 (25)
| I0 | The door from ASU SA oven S1 is included in the conditions to get the safety relay activation for carton section. |
| I1 | The door from ASU SA oven S2 is included in the conditions to get the safety relay activation for carton section. |
| I2 | Magazine door S1 |
| I3 | Magazine door S2 |
| I4, I5 | Not used |
| I6 | This feedback signal monitors the off state on safety relay for moving splice table on S1 |
| I7 | This feedback signal monitors the off state on safety relay for moving splice table on S2 |
| IQ10 | Dynamic output pulse +10V (A-Pulse) created in the Pluto system. |
| IQ11 | Dynamic signal from Adam E sensor on splice board hatch and reel door are connected in serial. |
| IQ12 | This IQ has a double function. It is an input for +10V and an output for +18V |
| IQ13 | Dynamic signal from Adam E sensor on splice board hatch and reel door are connected in serial. |
| IQ14 | This IQ has a double function. It is an input for +10V and an output for +18V |
| IQ15, IQ16 | Not used |
| IQ17 | This output is on (LED lit) when everything in the Pluto module is ok.If a fault occurs (shown by Er and a number in the display) or if a signal fail to come, for instance a feedback signal, (shown by UE and a number) the output goes off. |
| 0L | Supply terminal for relay output Q0. (Comes from a PLC output). |
| Q0 | This output is activated when the magazine door S1 is closed |
| 1L | Supply terminal for relay output Q1. (Comes from a PLC output). |
| Q1 | This output is activated when the magazine door S2 is closed |
| Q2 | When opening the splice board hatch or reel door on side 1 (IQ11 is off) this output goes off.Note: This output delivers -24V. This means that expansion relays or contactors connected to it must be connected in opposite polarity. (Machine L10 to + or A1 and Q2 to - or A2). |
| Q3 | When opening the splice board hatch or reel door on side 2 (IQ13 is off) this output goes off.Note: This output delivers -24V. This means that expansion relays or contactors connected to it must be connected in opposite polarity. (Machine L10 to + or A1 and Q2 to - or A2). |
Pluto - UE-Code List TTCU
Description of the Faults on each Pluto
The table below show the different faults on each Pluto unit, for a description of the faults see Description of the Faults on each Pluto on page Description of the Faults on each Pluto or Pluto - UE-Code List TT/3 on page Pluto - UE-Code List TT/3.Pluto 27 (TTCU) F73A0200
| Description | UE-code | I/O | Remark |
| One channel missing | 00 | I0, I1 | Emergency stop |
| One channel missing | 02 | I2, I3 | External e-stop |
| | | |
| Two channel fault | 01 | I0, I1 | Emergency stop |
| Two channel fault | 03 | I2, I3 | External e-stop |
| | | |
| Missing feedback | 07 | I7 | Feedback e-stop |
| | | |
| Constant reset | 11 | IQ11 | Reset |
Description of Different Fault Reasons TTCU
Two Channel Fault
- Reason 1: One of the channels (inputs) may have got a short interruption but is OK again.
- Symptom 1: The system will trip but it will not automatically reset when the input is OK again.
- Indication 1: The LED to the faulty input will flash and the information output to the PLC, will be off.
- Reset 1: Repair the faulty circuit, open and close both channels (for example by pushing and releasing the TTCU emergency stop and the TTCU reset push button) and then reset the alarm on the TPOP.
- Reason 2: One or both channels are permanently off.
- Symptom 2: The system will trip and is not possible to reset.
- Indication 2: The LED to the faulty input is off.
- Reset 2: Repair the faulty circuit, open and close both channels (for example by pushing and releasing the TTCU emergency stop, and the TTCU reset push button) and then reset the alarm.
Fault on the L21 power line (see the Electrical Manual)
- Reason: A broken power supply or a bad connection somewhere i the L21 line.
- Symptom: It is not possible to reset the system.
- Indication: In this case the Jokab component is OK and reset but there is still no power on the L21 line.
- Reset: Repair the L21 line and then reset the alarm.
Missing Feedback
- Reason: One of the feedback circuits has not been closed when the output has tripped.
- Symptom: It is not possible to reset the system.
- Indication: The LED to the faulty input (feedback circuit) will be off and the information output to the PLC will be off. The Pluto display will also show an UE-code describing to the fault, see Procedure Reference on page Reference
- Reset: Repair the faulty circuit or contactor and then reset the alarm
Pluto - UE-Code List TT/3
Pluto 3 (Machine 1) and Pluto 23 (Machine 2) in the Main Electrical Cabinet F03K0014
| Description | UE code | I/O | Remark |
| One channel missing | 00 | I0, I1 | Emergency stop |
| Two channel fault | 01 | I0, I1 | Emergency stop |
| | | |
| One channel missing | 02 | I2, I3 | External Emergency stop |
| Two channel fault | 03 | I2, I3 | External Emergency stop |
| | | |
| Missing feedback | 04 | I4 | Emergency Stop |
| Missing feedback | 05 | I5 | UV-Power S1 |
| Missing feedback | 06 | I6 | UV-Power S2 |
| Missing feedback | 07 | I7 | Package Section Servo |
| | | |
| Bus fault | 84 | | Pluto 4 or 24 missing |
| Bus fault | 85 | | Pluto 5 or 25 missing |
| Bus fault | 87 | | Pluto 27 missing when clean request is activated |
Pluto 4 (Machine 1) and Pluto 24 (Machine 2) in the Main Electrical Cabinet F03K0016
| Description | UE code | I/O | Remark |
| One channel missing | 00 | I0, I1 | Service Switch |
| Two channel fault | 01 | I0, I1 | Service Switch |
| | | |
| Missing feedback | 05 | I5 | Hatches Carton/Package |
| Missing feedback | 06 | I6 | Carton Section Servo |
| Missing feedback | 07 | I7 | Hydraulic Pump Carton |
| | | |
| Constant Reset | 14 | IQ14 | Reset Relay |
| | | |
| Bus fault | 83 | | Pluto 3 or 23 missing |
| Bus fault | 85 | | Pluto 5 or 25 missing |
| Bus fault | 87 | | Pluto 27 missing when clean request is activated |
Pluto 5 (Machine 1) and Pluto 25 (Machine 2) in the Electrical Cabinet in the ASU F03K0024
| Description | UE code | I/O | Remark |
| Missing feedback | 06 | I6 | Expansion Relay ASU S1 |
| Missing feedback | 07 | I7 | Expansion Relay ASU S2 |
| | | |
| Constant Reset | 12 | IQ12 | Reset Button ASU S1 |
| Constant Reset | 14 | IQ14 | Reset Button ASU S2 |
| | | |
| Bus fault | 83 | | Pluto 3 or 23 missing |
| Bus fault | 84 | | Pluto 4 or 24 missing |
| Bus fault | 87 | | Pluto 27 missing when clean request is activated |
Description of Different Fault Reasons TT/3
Two channel fault
- Reason 1: One of the channels (inputs) may have got a short interruption but is OK again.
- Symptom 1: The system will trip but it will not automatically reset when the input is OK again.
- Indication 1: The LED to the faulty input will flash and the information output to the PLC, will be off.
- Reset 1: Repair the faulty circuit, open and close both channels (for example by pushing and releasing an emergency stop button) and then reset the alarm.
- Reason 2: One or both channels are permanently off.
- Symptom 2: The system will trip and is not possible to reset.
- Indication 2: The LED to the faulty input is off.
- Reset 2: Repair the faulty circuit, open and close both channels (for example by pushing and releasing an emergency stop button) and then reset the alarm.
Fault on the L12 power line (see the Electrical Manual)
- Reason: A released fuse, a broken power supply or a bad connection somewhere i the L12 line.
- Symptom: It is not possible to reset the system.
- Indication: In this case all Jokab components are OK and reset but there is still no power on the L12 line.
- Reset: Repair the L12 line, push and release an emergency stop button and then reset the alarm.
Missing Feedback
- Reason: One of the feedback circuits has not been closed when the output has tripped.
- Symptom: It is not possible to reset the system.
- Indication: The LED to the faulty input (feedback circuit) will be off and the information output to the PLC will be off. The Pluto display will also show an UE-code describing to the fault, see Procedure Reference on page Reference
Reset: Repair the faulty circuit or contactor and then reset the alarm.
Pluto B20 Troubleshooting - Fault Code List
Status Messages
| No: | Description |
| - - | Power up |
| N n | Run mode (nn = station number) |
| Lo | Program load mode state.Flashing Lo, ready for self programming (program found in other unit). |
| HA | Program execution stopped from PC computer or not started after program download. |
User Faults
| No: | Fault and possible reason | Reset action |
| Er10 | Dynamic output short circuit to foreign voltage | Automatically reset. |
| Er11 | IQ_for illuminated push button function. Missing diode | Automatically reset. |
| Er12 | Short circuit between two dynamic inputs | Automatically reset. |
| Er13 | Static output Q10...Q17 short circuits to 0V or Q2-Q3 overloaded | K button, power off/on |
| Er14 | Static output Q10...Q17 short circuits to 24V | Automatically reset. |
| Er15 | Power supply below 18V | Automatically reset in 3 minutes or K button. |
| Er16 | Power supply above 30V | Automatically reset in 3 minutes or K button. |
| Er17 | | |
| Er18 | CAN-bus fault.(Short circuit, termination resistor, etc.) | Automatically reset in 3 minutes or K button. |
| Er19 | Other unit same station ID on CAN-bus. | |
| Er20 | PLC-program not loaded | Load of program according to Pluto - Replace in an Existing Application. |
| Er21 | PLC-program CRC-error | Reload with valid PLC-program. |
| Er22 | Identifier problem. External identifier can not be read. | Power off/on |
| Er23 | Unmatched ID. Identifier does not match declaration in program. | Exchange of identifiers or re-declaration of identifier in program. |
| Er24 | Erroneous PLC-code. Invalid PLC-instructions. | Reload with valid code. |
| Er25 | For version A16. Non existing output used in program. | |
| Er26 | Baud rate conflict. Unit programmed for other baud rate than current bus baud rate. | Reprogram according to Pluto - Download Program from a PC or reboot. |
| Er27 | Wrong checksum for unit member in common program. | Reprogram according to Pluto - Download Program from a PC or reboot. |
| Er28 | PLC program does not match the Pluto family. | Change to other type of Pluto or change the program. |
| Er29 | Unsupported program version. The program contains instructions only supported by later customer specific operating system. | Update the operating system. |
I/O Faults
| No: | Fault and possible reason | Reset action |
| Er40 | Error output Q0-Q3 | K button |
| Er41 | Error output Q2 or Q3. Overload or foreign voltage. | K button |
| Er42 | Error output Q0 or Q1. (No answer from relay monitoring) | K button |
| Er43 | Error output Q0 or Q1. (Self test of transistors) | Power off/on |
| Er45 | Analogue functions not calibrated. | System must be calibrated |
| | |
| Er49 | Error calibration values, analogue functions | Recalibration |
CPU Faults
| No: | Fault and possible reason | Reset action |
| Er50 | Input data difference between processor A and BProcessor A and B reads an input differently. The fault is often caused by a bad sensor.Corresponding input LED flashes. | Power off/on |
| Er51 | Output data difference between processor A and B.Processor A and B sets a global variable different (Q0..Q3, GM0..11).(The problem can be caused by the PLC-program). | Power off/on |
| | |
| Er59 | Calibration analogue functions CRC fault | Power off/on |
| Er60 | Twin self test monitoring | Power off/on |
| Er61 | Timer IRQ monitoring | Power off/on |
| Er62 | Internal serial communication | Power off/on |
| Er63 | Boot-flash CRC | Power off/on |
| Er64 | OS-flash CRC | Power off/ont, reload operating system. |
| Er65 | PLC-flash CRC | Power off/on, reload PLC program |
| Er66 | 5 volt under/over voltage monitoring | Power off/on |
| Er67 | CPU-test error | Power off/on |
| Er68 | Ram-test error | Power off/on |
| Er69 | Scan cycle time over run | Power off/on |
| Er70 | System, sum of system and stack monitoring | Power off/on |
| Er71 | Pluto used for IDFIX writing. Normal operation ceased | Power off/on |
| Er80 | Undefined self-test error | Power off/on |
Functional Description
The HMI is the control software that is graphically represented on the touch screen as an interface for operating and controlling filling machines.PLMS is the data management system for collecting, analysing, and monitoring the operational performance of filling machines and packaging lines.Note: The NRG logger stops working if the communication between configured distribution equipment and TPOP breaks for some reason. For example, if:- TPOP is restarted when the distribution equipment is switched off.
- the distribution equipment is restarted.
- the distribution equipment loses power.
If this happens, make sure the configured distribution equipment is switched on, communication is re-established, and restart the TPOP. For instructions on how to check communication status, see Section PLMS NRG – DE Overview.
DE = Distribution Equipment
- TPOP computer box, APC
- TPOP display unit, AP920
- Line supervision
- Serial communication
- PLMS Master PC
- Network connection
- Remote PC
- Telephone connection
- Remote PC
PLC, HMI and PLMS - Check Version
| Equipment Status | Program Step step zero |
- Press System overview.

- System overview
| 2 | Press for alarm history. |
| 3 | Press for program changes. |
| 4 | HMI release number and HMI release date. HMI release date is logged by PLMS at every date change as Event code 110001510. |
| 5 | PLC Logic release number and PLC Logic release date. An optional PLC Logic local will show up if stated to something else than 0 in the PLC Logic program, see Procedure PLC Controller - Mark and Trace Local PLC Adaptations. The PLC tag is: HMI.HMI_110001520_PlcLogicLocal. PLC Logic release date are logged by PLMS at every date change as Event code 110001520 and 110001530. |
| 6 | PLC Motion release number and PLC Motion release date. An optional PLC Motion local will show up if stated to something else than 0 in the PLC-Motion program, see Procedure PLC Controller - Mark and Trace Local PLC Adaptations. The PLC tag is: Motion_HMI_110001540_PlcMotionLocal. PLC Motion release date are logged by PLMS at every date change as Event code 110001530 and 110001540. |
| 7 | Cap Vision S1 and S2. |
| 8 | Machine number and PLMS configuration version release date. This is logged as Event code 110001020. |

- Alarm history
- Program changes
- HMI
- PLC logic
- PLC motion
- CAP vision
- PLMS
HMI and PLMS - Log on Procedure
| Equipment Status | Program Step |
| Special Equipment | Keyboard with USB connector |
When the machine is switched on, the system automatically logs on as operator. This allows the daily use of the machine. For some purposes you will need to log off as operator and log on as an installer.The installer has greater privileges and is allowed to:- install software
- change configuration
- change date and time
Log on as Installer
- Open the Operator panel door.
- Connect a keyboard to one of the USB port on the display unit.
- Press Ctrl + Esc and select
Log off operator from the Start menu. Click Yes or press Enter. Log on with the following identity:- USER NAME:
installer - PASSWORD:
installer
- Logged on as installer you can use the Start menu to perform the necessary tasks.

- Operator panel door
- USB port
Restart the TPOP
- Press Ctrl + Esc and select
Shut down from the Start menu. - Select
Restart from the list and click OK or press Enter. - Remove the keyboard and close the operator panel door.
The system is now restarted in normal operating mode.
HMI and PLMS - Install Software
| Equipment Status | Program Step step zero |
| Special Equipment | TPOP BASIC DVD Keyboard with USB connector |
Required Material for Machines with Industrial PC APC620
- TPOP Basic DVD
- Software USB key
Required Material for Machines with Industrial PC APC910 gen 3
- TPOP Basic USB key
- Software USB key
Installation Order
You must always follow the order below when installing software. If you are only updating one or more of the programs then jump directly to the specific software sections.For machine with APC620- TPOP Basic DVD
- Easy Suite for TPOP and PLMS Installation
For machine with APC910 gen 3- TPOP Basic USB key
- Easy Suite for TPOP and PLMS Installation
- Disconnect the supply voltage +24 VDC to the APC.
- Open the door to the carton section S1 and connect a keyboard to one of the panel USB connectors.Note: Do not connect a mouse when installing TPOP basic.
TPOP Basic DVD APC620
| Equipment Status | Program Step step zero |
| Special Equipment | TPOP BASIC DVD |
Risk of damage to the equipment.For a correct installation of the software in an empty hard disc drive or a complete reinstallation including formatting the HDD, follow exactly the order of the instructions below.If the instruction order below is not followed exactly the installation may be incorrect.
- Insert the TPOP Basic DVD in the DVD-drive.
- Press Ctrl + Esc and choose
Shut down from the Start menu. - Choose
Restart and press OK. - Press any key when the text Press any key to boot from DVD is displayed.Note: This text will only be displayed for a few seconds, and then the computer continues with a normal boot. If it does, wait until it is finished, and repeat from item .
- The operating system and TPOP Basic is now being installed and configured. The process will take approximately 40 minutes.Note: There is no need of user interaction until the Date and Time window appears. The TPOP Basic DVD is automatically ejected when the installation is completed.
- Enter current date and time.
- Click
Finish.
Note: After the installation of the TPOP Basic USB, it is necessary to install more software. See Procedure .TPOP Basic USB Key APC910 gen 3
| Equipment Status | Program Step STEP ZERO |
| Special Equipment | TPOP BASIC DVD/USB Keyboard with USB connector |
- Insert the USB key with the program for TPOP Basic in a USB port of the APC.
- Press CTRL + ESC and choose Shut down from the Start menu.
- Choose Restart and press OK.
- Immediately at the boot, as soon as the APC shows the BIOS screen, press F11 to select the Boot device and press ENTER.
- Locate in the list the USB media and select it using the ARROW keys (in the picture the USB media is identified as GENERIC FLASH DISK), then press ENTER on the keyboard to continue.Note: The USB media could show different names depending on manufacturer.
- The Windows XP environment starts and the installation proceeds.Note: The installation process will take approximately 35 minutes in total. The HMI will be restarted a couple of times.
- When prompted, enter the current date and time and press enter.
- Remove the TPOP Basic software USB key from the APC.Note: If the TPOP Basic software USB key is not removed, it will not be possible to install the PLMS NRG, HMI, PLMS Logger Config as an installer.
- Press the FINISH button to complete the installation.
- Continue to install the PLMS NRG, HMI, PLMS Logger Config and other software,
APC910 gen 3 BIOS settings for Dual Display
If the APC910 is delivered from supplier with preconfigured BIOS, the same changes have to be done to get the dual display to work. The BIOS is the low level software managing the hardware and providing resources to the operating system and applications running at higher level.To access the BIOS you have to connect a keyboard to the APC and then turn on the unit. At power up press del or F2 to enter the BIOS configuration utility.The Tetra Pak configuration differs for just few settings from the standard B&R configuration. If you have doubts about which configuration is present on the APC, it is suggested to press F9 to load the optimized values and then apply the Tetra Pak specific settings manually.When in the BIOS configuration, use arrow keys to move between the different menus.- Select
Advanced and Graphics configuration.
- As Primary IGFX Boot Display select VBIOS Default.
- Enable the Display Port C Interface and select HDMI / DVI.
- Then return in
Advanced by pressing ESC and then select Advanced and OEM Features.
- Select super I/O Configuration.
- Enable the following serial ports:
- Serial port A: Enabled (com1, IO=3F8h, IRQ=4)
- Serial port B: Enabled (second SDL card, if present)
- Serial Port C: Enabled (touch screen panel, IO=3E8h, IRQ=11)
- Serial Port E: Enabled (Rs485 port, IO=2E8h, IRQ=10)
By pressing ESC return to the main menu level and then select.
- When the setting procedure is completed press F10 to Save and Exit.
HMI and PLMS - Install Software
| Equipment Status | Program Step step zero |
| Special Equipment | TPOP BASIC DVD Keyboard with USB connector |
Required Material for Machines with Industrial PC APC910 gen 6
- TPOP Basic USB key
- Software HMI License Installer USB key
- Software USB key
Installation Order
You must always follow the order below when installing software. If you are only updating one or more of the programs then jump directly to the specific software sections.- TPOP Basic USB key
- Software HMI License Installer USB key
- Easy Suite for TPOP and PLMS Installation
- Disconnect the supply voltage +24 VDC to the APC.
- Open the door to the carton section S1 and connect a keyboard to one of the panel USB connectors.Note: Do not connect a mouse when installing TPOP basic.
TPOP Basic USB Key APC 910 Gen 6
| Equipment Status | Program Step STEP ZERO |
- Insert the USB key with the program for TPOP Basic in a USB port of the APC.
- Press CTRL + ESC and choose Shut down from the Start menu.
- Choose Restart and press OK.
- Immediately at the boot, as soon as the APC shows the BIOS screen, press F11 to select the Boot device and press ENTER.
- Locate in the list the USB media and select it using the ARROW keys (in the picture the USB media is identified as GENERIC FLASH DISK), then press ENTER on the keyboard to continue.Note: The USB media could show different names depending on manufacturer.
- The Windows 10 environment starts and the installation proceeds.Note: The installation process will take approximately 35 minutes in total. The TPOP will be restarted a couple of times.
Risk of losing dataIt is recommended a backup of the data before starting the procedure.
- When the boot is completed a list of possible options is prompted.Note: The IPC is equipped with two disks: the first contains the operating system (volume C:), the second contains the log data (volume D:).
- Enter the value depending on the option selected:
- type c to clean the disks, creating new partitions and then applying WIN images: all the data in the disks are removed and the disks are formatted. This option is to be used when a complete cleanup of the system is needed.
- type b to restore the boot partition: it is to be used when the IPC is failing at boot after power up due a corrupted boot partition. This option restores only the boot partition preserving the existing system information and log data.
- type s to restore the system partition, preserving the existing log data in the volume D:. With this option only the first disk is formatted but the second disk is kept unchanged.
- type p to go the prompt command (only for advanced users).
- type e to exit the installation procedure without changing the disk content.
- When c is selected, the system warns that the action will erase all the data in the unit and restore the original image. Enter y to confirm or enter n to abort. Entering y the procedure starts and takes about 15-20 minutes. Go to step Reference.
- When b is selected, the system warns that action will restore the boot partition. Entering y to confirm, the procedure starts and takes about 1-2 minutes.
- When s is selected, the system warns that the action will erase the system partition and restore the original image, preserving the data logger partition. Enter y to confirm, the procedure starts and takes about 15-20 minutes.
- When the procedure is completed, remove the USB restore key, press R and then ENTER. The system will restart.
- The APC will restart several times. Do not do anything until you are prompted about date and time.
- Set the current date and time when prompted.
- The system is then rebooted and automatically logged in as "installer". Proceed with the installation of PLMS Logger and Config, the HMI application and additional software.
- Attach the self adhesive label with the text shown in the picture on the IPC front panel.
APC910 Gen 6 BIOS settings for Dual Display
| Equipment Status | Program Step STEP ZERO |
Note: If two screens are already in use, ignore this instruction.If the APC910 is delivered from supplier with preconfigured BIOS, the same changes have to be done to get the dual display to work. The BIOS is the low level software managing the hardware and providing resources to the operating system and applications running at higher level.To access the BIOS you have to connect a keyboard to the APC and then turn on the unit. At power up press del or F2 to enter the BIOS configuration utility.The Tetra Pak configuration differs for just few settings from the standard B&R configuration. If you have doubts about which configuration is present on the APC, it is suggested to press F9 to load the optimized values and then apply the Tetra Pak specific settings manually.When in the BIOS configuration, use arrow keys to move between the different menus.- Select
Advanced and Graphics configuration.
- Enable the DIGITAL DISPLAY INTERFACE 2 and select HDMI / DVI.
- Then return in
Advanced by pressing ESC and then select Advanced and OEM Features.
- Select super I/O.
- Enable the following serial ports:
- Serial port A: Enabled (com1, IO=3F8h, IRQ=4)
- Serial port B: Enabled (second SDL card, if present)
- Serial Port C: Enabled (touch screen panel, IO=3E8h, IRQ=11)
- Serial Port E: Enabled (Rs485 port, IO=2E8h, IRQ=10)
By pressing ESC return to the main menu level and then select.
- When the setting procedure is completed press F10 to Save and Exit.
HMI and PLMS - Install PLMS NRG, TPOP HMI, and PLMS Configuration
| Equipment Status | Program Step step zero |
| Special Equipment | Keyboard with USB connector Machine Software disc |
Note: The NRG logger stops working if the communication between configured distribution equipment and TPOP breaks for some reason. For example, if:- TPOP is restarted when the distribution equipment is switched off.- the distribution equipment is restarted.- the distribution equipment loses power.If this happens, make sure the configured distribution equipment is switched on, communication is re-established, and restart the TPOP. For instructions on how to check communication status, see Section PLMS NRG – DE Overview.- Log on as an installer.
- APC620:Insert the disc marked Machine Software into the optical drive of the APC.APC910:Insert the USB key with the Machine Software in a USB port of the APC.
- From the
Start menu select None*.(*the drive letter is different depending on the machine configuration.) - The Installation screen appears. If you want to read about the different programs select ReadMe and press About.Note: If both PLMS Logger and PLMS Config are to be installed, PLMS Logger must always be installed before PLMS Config.

- Installation screen
- ReadMe
- About
- Select the software to be installed, according to the list as follows, and press About.
- Read the information about the software and close the information window.
Risk of failure of software installation.Do not press
Start Installation more than once.Some installations may take long time to start.
Make sure that the software to be installed is still selected and press Start Installation.10 Panel settings (APC620)11 Panel settings (APC910)When installing 11 Panel settings (APC910), follow the instructions in Procedure Auto-detect touch screen.12 (APC620)13 (APC910)20 Note: When installing 20 PLMS Logger NRG, make sure that the checkbox Launch PLMS NRG Configuration is not checked.Note: If the PLMS NRG logger is reinstalling, the setup message The installation might have failed. Please reboot the computer and install again. can be shown. If this happens, reboot the computer and install again.21 (APC620)When installing 21 , follow the instructions in Procedure TPOP and PLMS - Reinstall MSMQ Triggers.30 Runtime License40 50 60-7x Select Note: Only install SNP config files for the DE used.99 Configure

The text in the window will differ from the illustration above.
- About
- Start Installation
- Exit
- Follow the instructions on the screen, and when prompted accept the default values.
- Repeat the procedure from item Reference to install more software.
- Press Exit when all the necessary software has been installed.
- Remove the Machine software disc from the optical drive of the APC reader when the installation is finished.

The text in the window will differ from the illustration above.
- About
- Start Installation
- Exit
- If you do have disconnected the panel on side 2, you have to connect it before you continue. Disconnect the supply voltage +24 VDC (A250) and connect the SDL cable for the S2 panel. Then connect the supply voltage.
- To activate the panel on side 2 press Ctrl + Alt + F12.
- Select Intel Dual Display Clone and press OK.

- Intel Dual Display Clone
- OK
- Close the pop up window by pressing OK.

- OK
- Restart the TPOP and log on as operator.
Auto-detect touch screen
- Open the Touch Screen Properties from the installation disk, Panel settings (APC910).
- Press the
Select button.
- Press the
Auto-Detect button.
- Close and exit Touch Screen Properties.
HMI and PLMS - Reinstall MSMQ Triggers
- Open the control panel from the installation disc, MSMQ.
- Select
Add or Remove Programs in the control panel. - Select
Add/Remove Windows Components. - Select
Message Queuing - Select
Details. - Select
Triggers. - Select
OK. - Select
Next. - Select
Finish. - Close the
Add or Remove Programs window. - Close the control panel.
- Restart the system, and then the logger should start without errors.
HMI and PLMS - Update DASAbcip Software
| Equipment Status | Program Step step zero |
| Special Equipment | CD with Software |
The DASAbcip software is a communication server distributed by Wonderware and used to implement communication between the TPOP and the Rockwell RSLogix PLCs. Due to the introduction of RSLogix v19, the DASABcip server has to be version4.1Sp2. The TPOPBasic3.3 already implements this version of DASAbcip, but previous TPOPBasic3.1and3.2 do not (e.g. 3.2 contains Dasabcip 4.0.0).A WinRar self-extracting archive contains the needed file to install the DASAbcip server and auxiliary software as MicrosoftC++ redistributable libraries and the Sentinel Protection. To simplify the installation, some specific parameters are automatically set by the installation procedure, which is implemented with an AutoItv3script.Installation Procedure
- Log on as an installer on the TPOP. See Procedure HMI and PLMS - Log on Procedure.
- Self-extraction of the files into the folder .
- Start of the installation procedure. Click
None.
- In case of refusal, the below message is shown. The installation must be restarted when possible.
- In case the installation files are already present in the destination directory, you could overwrite them by selecting
None in the confirmation window.
- The setup procedure is divided in 5 steps and restart should be postponed at least to the completion of the procedure.
- The procedure will automatically stop the DASAbcip server to allow installation of the software components.
- Setup of the Microsoft Visual C++ Redistributable libraries. Click
None to proceed.
- Accept license terms and installation of libraries.
- At completion of the installation of the libraries, click
None.
Installation of Sentinel Protection
- Proceed with the Installation of Sentinel Protection by clicking
None.
- Upgrade the current installation of the Sentinel Protection.
- At the Welcome screen, click
None.
- Accept the license terms.
- Select the default complete setup type.
- Proceed with Installation.
- Click
None when requested.
- Complete the installation by clicking
None.
- Do not restart the TPOP when requested. Click
None.
Installation of the DASAbcip Server
- Click
None to confirm the compatibility check request.
- Click
None at the Welcome screen of ABCIP DAServer upgrade.
- Accept the License Agreement and click
None.
- Click
None to confirm.
- Click
None to confirm the update to version4.1.2 from previous installation.
- Do not change default setup options. Confirm by clicking
None.
- Click
None to start the installation of the DASAbcip server.
- Click
None to close server setup procedure.
- Do not restart the TPOP. Click
None. Additional settings are needed before restarting the TPOP.
Final Settings Procedure
- Confirm with
None to start the final settings procedure.
- Click
None to confirm the completion of the whole setup procedure. The new server is now installed and configured. A reboot is needed to apply all the changes but it could be deferred in case of planned additional installations. Please reboot the system as soon as the maintenance process is completed.
Installation Completed
Note: In case you try to apply the procedure to a DASAbcip installation which is already updated, you will get the possibility to repair the existing installation. In this case some steps will differ from the described procedure. Especially at point 5 you will have to select the Repair option:- Repair the Microsoft Visual C++ 2008 Redistributable libraries.
- Choose to postpone restart when prompted by deselecting Restart the computer option and then click
None
- You will be asked to modify the current Sentinel Protection installation.
- Select Repair and click
Next.
- Do not restart the system. Click
No when asked to restart the system.
- At the ABCIP DAServer setup, select Repair and click
Next.
HMI and PLMS - Install InTouch License
| Equipment Status | Program Step STEP ZERO |
| Software License Handling (3660971-0100) |
| 1900 | A050:2 |
| 2000 | A01C0008 |
- Insert the software media in the TPOP USB port.
- From the
START menu select INSTALLATION FROM DRIVE E. - The installation screen appears. Select the HMI Licence Installer. Touch the Start Installation Button.
- Follow the instructions on the screen, and when prompted accept the default values.
- When the license installation is completed, touch the Exit Button.
- Remove the USB.

HMI Licence InstallerStart Installation ButtonExit Button
HMI and PLMS - Install PLMS NRG, TPOP HMI, and PLMS Configuration APC910 Gen 6
| Equipment Status | Program Step step zero |
| Special Equipment | Keyboard with USB connector Machine Software USB |
Note: The NRG logger stops working if the communication between configured distribution equipment and TPOP breaks for some reason. For example, if:- TPOP is restarted when the distribution equipment is switched off.- the distribution equipment is restarted.- the distribution equipment loses power.If this happens, make sure the configured distribution equipment is switched on, communication is re-established, and restart the TPOP. For instructions on how to check communication status, see Section PLMS NRG – DE Overview.- Log on as an installer.
- Insert the USB key with the Machine Software in a USB port of the APC.
- From the
Start menu select None.
- The Installation screen appears. If you want to read about the different programs select ReadMe and press About.Note: If both PLMS Logger and PLMS Config are to be installed, PLMS Logger must always be installed before PLMS Config.

- Installation screen
- ReadMe
- About
- Select the software to be installed, according to the list as follows, and press About.
- Read the information about the software and close the information window.
Risk of failure of software installation.Do not press
Start Installation more than once.Some installations may take long time to start.
- Make sure that the software to be installed is still selected and press Start Installation.
15 TPOP settings (APC-910Gen6)Note: Settings installed, need to be adjusted, follow instruction in item (n) Setup dual screen lock.21 Note: When installing 21 PLMS Logger NRG 460, make sure that the checkbox Launch PLMS NRG Configuration is not checked.Note: If the PLMS NRG logger is reinstalling, the setup message THE INSTALLATION MIGHT HAVE FAILED. PLEASE REBOOT THE COMPUTER AND INSTALL AGAIN. can be shown. If this happens, reboot the computer and install again.Note: The computer will restart in operator mode. You have to log on as installer.41 50

The text in the window will differ from the illustration above.
- Start Installation
- Follow the instructions on the screen, and when prompted accept the default values.
- Repeat the procedure from item Reference to install more software.
- Press Exit when all the necessary software has been installed.
- Remove the Machine software USB from the APC when the installation is finished.
- Restart the TPOP.

The text in the window will differ from the illustration above.
- Exit
Set up Dual Screen Lock
- Connect a keyboard to the APC and press button with Windows symbol (down to the left on the keyboard).
- Select the button B&R Control Center.

B&R Control Center
- When the window
B&R Control Center is opened, select the Keys tab. - Press the Update button to navigate to the path where you can find and select the file with the correct time setting for dual screen lock.
- Navigate to C:\Utility\2Panel_10s and select the file
2Panel_10s.kcf. 
KeysUpdateAdvanced button- Panel Status
- Panel selection
- Select Open.

Open
- Now the installation of the Dual screen lock is ongoing. Do NOT interrupt the installation. Do NOT disable any screen during installation.
- When the following popup is shown, the installation is finished. Select Close.

Close
- To view the setting just installed, select Advanced.

Advanced
- The following popup is shown and the value 10000 ms should be visible in the square for Lock time.
- Press Cancel.

Lock timeCancel
- To check the lock function, Press the Panel selection to change the Panel Status from
AP Link (0) to AP Link (8). Touch the panel. The Panel Status should change from Unlocked to Locked.Note: This instruction assumes that the installation takes place from Machine side 1 - Press
OK. 
- Panel Status
- Panel selection
- Restart the TPOP.
Set Up Dual Screens Manually
Note: If two screens are already in use, ignore this instruction.- Press the Windows button and p.
- Choose the Duplicate option.
Auto-detect touch screen
Note: If two screens are already in use, ignore this instruction.- Open the Touch Screen Properties from the installation disk, Panel settings (APC910).
- Press the
Select button.
- Press the
Auto-Detect button.
- Close and exit Touch Screen Properties.
PLMS NRG Configurator Description
PLMS NRG is used to access the PLMS components that can be enabled and configured when logged on as an installer. Touch the Exit NRG configuration button to save any changes done and exit from the program.
- PLMS NRG main window
- PLMS NRG configuration button
- Distribution equipment setup button
- Operator sheet standard setup button
- Hardware and network button
- Exit NRG configuration button
PLMS NRG Configurator - Set path to log data
| Equipment Status | Power must be turn OFF.
|
| Special Equipment | Keyboard with USB connector |
- Make sure that the correct path is used for the log data. If the PC has one drive use c:\logger\data\ and if it has two drives use d:\logger\data\ as the Path to the log data.

- Path to the log data
PLMS NRG Configurator - Set Machine ID
| Equipment Status | Power must be turn ON.
|
| Special Equipment | Keyboard with USB connector |
Risk of machine program fault.The PLC program is associated to the machine serial number. Make sure to set the correct serial number to load the correct PLC program version.
Note: It is very important to keep the old PLMS Centre number, that was used for the machines before NRG was installed. To do this you have to enter the machine type of the machine in the Serial Number box and the serial number of the machine in the Machine Type box.- Log on as an installer, see HMI and PLMS - Log on Procedure.
- From the Start menu choose Configure PLMS.
- If you have an old PLMS Center number, from before NRG was installed, see illustration A and do the following:
- In the PLMS NRG Configurator window, touch the Machine type field to activate it and enter the Serial Number from the machine plate with the keyboard.
- Touch the Serial number field to activate it and enter the Machine Type from the machine plate with the keyboard.
- If you do not have an old PLMS Center number, from before NRG was installed, see illustration B and do the following:
- In the PLMS NRG Configurator window, touch the Machine type field to activate it and enter the Machine Type from the machine plate with the keyboard.
- Touch the Serial number field to activate it and enter the Serial Number from the machine plate with the keyboard.
- Restart and log on as an operator, see HMI and PLMS - Log on Procedure.

- Machine type field
- Serial number field
PLMS NRG - Install DE Config Files
| Equipment Status | Power must be turn ON.
|
| Special Equipment | Keyboard with USB connector Laptop PC |
The Config file of each DE must be installed on the filling machine IPC. Proceed as follows:- Connect a keyboard to a port on the control panel and log on as an installer, see HMI and PLMS - Log on Procedure.
- Insert the software CD of the DE in the laptop PC CD drive and copy the config file setup.exe into a USB key.
- Remove the USB key from the laptop PC and insert it in a USB port of the TPOP.
- From the start menu choose TPOP installation from drive F:\
- The following dialogue box appears. Select the Yes button.Note: The name of the DE name being installed is displayed in the dialogue box.

- Yes button
- DE name
- When the installation is completed, a dialogue box appears.
- Select the OK button.
- Repeat the same procedure to install the config files of all the DE of the line.
- When all the DE config files have been installed, restart and log on as an operator, see HMI and PLMS - Log on Procedure.

- OK button
PLMS NRG Configurator - Distribution Equipment Setup
| Equipment Status | Power must be turn ON.
|
| Special Equipment | Keyboard with USB connector |
- Log on as an installer, see HMI and PLMS - Log on Procedure.
- From the Start menu choose Configure PLMS.
- Touch the Distribution equipment setup button in the PLMS NRG window.

- Distribution equipment setup button
- Uncheck the Enable ethernet scanning box, see Reference.
- Make sure that the Enable catch DE box is selected

- Distribution equipment setup window
- Enable ethernet scanning box
- Enable catch DE box
- The DE cause alarm delay in seconds box has the following meaning in case:
- Fixed delay option button has been selected. Determines how long after an alarm in the distribution equipment is cleared, it will be held responsible for a stop in the filling machine when a conveyor congestion occurs.
- Dynamic delay option button has been selected. The maximum time in seconds that an alarm in the distribution equipment is cleared must be defined for every single DE in the line, for this amount of time the DE is held responsible for a stop in the filling machine when a conveyor congestion occurs. If selected the see Reference.Note: The above check boxes are not available if the Enable catch DE box is unchecked.

- Enable catch DE box
- DE cause alarm delay in seconds box
- Fixed delay option button
- Dynamic delay option button
Manual Line Configuration
- Every DE equipment in the line must be manually configured.
- Select a Position button that represents the position of the chosen DE in the packaging line configuration.

- Position button
- Change line in Edit which line. Line 1 represents side 1 on the TT/3. Line 2 represents side 2 on the TT/3.
- Specify the DE TYPE.
- SNP option button: valid for DE equipment equipped with GE Fanuc and SNP Connection. Then select the configuration file from the SNP DE List. Input the Serial number and the Nickname. Note: Odd numbers represent DE equipment on side 1 and even number represent DE equipment on side 2.
- Ethernet manual setup: valid for DE equipment equipped with Rockwell and Ethernet. Input the last four digits of IP address and the Nickname. Make sure that the DE index is set to 0(zero). For IP adresses to be used, see IP adress table Reference below. Note: The setup in the DE equipment must have the same IP-Adresses configured
- Repeat items Reference and Reference for all DE equipment on both lines.

- Edit which line
- SNP option button
- SNP DE List
- Serial number
- Nickname
- Ethernet manual setup
- IP address
- Nickname
- DE index
- Touch the Delete setup file button to delete a DE configuration.Delete all DE configurations that are not used.
- Touch the Export all distribution setups button to export a DE configuration.
- Touch the Import a distribution setup button to import a DE configuration.

- Delete setup file button
- Export all distribution setups button
- Import a distribution setup button
Advanced Manual Line Configuration
After the manual line configuration is completed, if necessary, it is possible to enable the dynamic delay to activate the following advanced functions.- The DE alarm priority check box define the priority of the alarms generated by the different DE in the line to identify the most important stop reason of the filling machine.Input a value from 0 to 10 where 0 is the highest priority.
- The DE cause alarm delay in seconds define the maximum time that an alarm in the distribution equipment is cleared, for this amount of time the DE is held responsible for a stop in the filling machine when a conveyor congestion occurs.

SNP DE Setup window

Ethernet Manual Setup window
- DE alarm priority check box
- DE cause alarm delay in seconds
IP-addresses
The IP-numbers listed below are used when connecting DE equipment to the machine.| Side 1 |
| PLC | HMI | Equipment |
| 10.0.0.201 | 10.0.4.201 | FM PLC |
| 10.0.0.202 | 10.0.4.202 | Accumulator |
| 10.0.0.203 | 10.0.4.203 | Prim. Applicator |
| 10.0.0.204 | 10.0.4.204 | Prim. Shrink / Stretch Wrapper |
| 10.0.0.205 | 10.0.4.205 | Sec. Applicator |
| 10.0.0.206 | 10.0.4.206 | Cardboard / Wrapper |
| 10.0.0.207 | 10.0.4.207 | Sec. Shrink / Stretch Wrapper |
| 10.0.0.208 | 10.0.4.208 | Elevator |
| 10.0.0.209 | 10.0.4.209 | Palletizer |
| 10.0.0.210 | 10.0.4.210 | Pallet Shrink / Stretch Wrapper |
| Side 2 |
| PLC | HMI | Equipment |
| 10.0.1.171 | 10.0.2.171 | Not Used |
| 10.0.1.172 | 10.0.2.172 | Accumulator |
| 10.0.1.173 | 10.0.2.173 | Prim. Applicator |
| 10.0.1.174 | 10.0.2.174 | Prim. Shrink / Stretch Wrapper |
| 10.0.1.175 | 10.0.2.175 | Sec. Applicator |
| 10.0.1.176 | 10.0.2.176 | Cardboard / Wrapper |
| 10.0.1.177 | 10.0.2.177 | Sec. Shrink / Stretch Wrapper |
| 10.0.1.178 | 10.0.2.178 | Elevator |
| 10.0.1.179 | 10.0.2.179 | Palletizer |
| 10.0.1.180 | 10.0.2.180 | Pallet Shrink / Stretch Wrapper |
PLMS NRG Configurator - Defragment the IPC Hard Disk
| Equipment Status | Power must be turn ON.
|
| Special Equipment | Keyboard with USB connector |
If the boot sequence for TPOP takes more time than can normally be expected, there is a possibility that the IPC hard disk requires defragmenting. To start the disk defragmenter perform the following:- Log on as an installer, see HMI and PLMS - Log on Procedure.
- From the start menu choose configure PLMS.
- Touch the Hardware and Network button .
- Touch the Defragment the hard disk button
- The following Warning message window appears.
- Select Yes button the to start the disk defragmenter.
The disk defragmenter is a system tool of Microsoft Windows, see the disk defragmenter help menu for more details on using the disk defragmenter.
- Hardware and Network button
- Defragment the hard disk button
- Warning message window
- Yes button
PLMS NRG Configurator - Set Date and Time
| Equipment Status | Power must be turn ON.
|
| Special Equipment | Keyboard with USB connector |
- Log on as an installer, see HMI and PLMS - Log on Procedure.
- From the Start menu choose Configure PLMS.
- Touch the Hardware and network, then touch the Time or date button in the PLMS Live window.

- Hardware and network
- Time or date button
- Use the Arrow button to change the time in steps of one hour, the Arrow button to change the time in steps of ten minutes, the Arrow button to change the time in steps of one minute, the Arrow button to change the time in steps of one second.
- Touch the OK button to save the new date and time.
- If all work with the PLMS is finished, restart and log on as an operator, see HMI and PLMS - Log on Procedure.

- Arrow button
- Arrow button
- Arrow button
- Arrow button
- OK button
- Touch the Time syncronization setup to select the time zone and the daylight saving time option. The TIME SYNCRONIZATION SETUP window appears.
- Enable the Attempt to synchronize time over a network check box to enable automatic date and time synchronization with the PLMS master PC.
- Select the country from the Country list and select the Check box if the daylight savings time should be adjusted automatically.
- If all work with the PLMS is finished, restart and log on as an operator, follow the instructions in procedure HMI and PLMS - Log on Procedure.

- Time syncronization setup
- Attempt to synchronize time over a network check box
- Country list
- Check box
PLMS NRG Configurator - Operator Sheet Set Up
| Equipment Status | Power must be turn ON.
|
| Special Equipment | Keyboard with USB connector |
- Log on as an installer, see HMI and PLMS - Log on Procedure.
- From the Start menu choose Configure PLMS.
- In the PLMS NRG Configurator window touch the:

- Operator sheet standard setup button
- Custom event code button
- Operator sheet automatic signals button
- If not already done, select the Enable operator sheet check box in the PLMS NRG Configurator main window.
- Restart and log on as an operator, see HMI and PLMS - Log on Procedure.

- Enable operator sheet check box
Operator Sheet Configuration
To configure the operator sheet using pre-defined event codes, proceed as follows:- Touch the Operator sheet button, see item Reference.
- If necessary modify the Present setup list:

- Present setup list
- Scroll button
- Delete button
- Original setup and unused codes list
- Scroll button
- Copy to here button
- In the Operator sheet time out in seconds field, set the time of how long inactivity from the operator is tolerated before the TPOP returns to the normal view.
- If necessary, in the Standard value field, set a standard value for selected event codes in the Present setup list, this is an optional input. Save the value with the Change standard value button.
- If the Event Code must or should cause a break in the log for later data analysis, enable the Check box. Normally the Check box should be disabled.

- Present setup list
- Operator sheet time out in seconds field
- Standard value field
- Change standard value button
- Check box
Configure Custom Event Codes
To configure the operator sheet using customer specific event codes, proceed as follows:The Custom event codes list is composed of an Event Code Description, associated to an Event Code between 103 2800 00 and 103 2999 00. Where 103 indicates the filler type and can not be changed, and 00 is reserved for PLMS and can not be changed.The Custom event codes list must be structured in:- Main group - 2800 or 2900- Sub group - 2810, 2910 and 2920 in this example- Detail - 2811, 2812, 2911, 2912 and 2921 in this example.Navigate in the Custom event codes list with the Scroll button.To remove an Event Code from the Custom event codes list, touch the Delete button.
- Custom event codes list
- Main group
- Sub group
- Detail
- Scroll button
- Delete button
To configure the operator sheet with customer specific event codes and add Event CodeS to the Custom event codes list, proceed as follows:- Touch the Add button.
- Write the Event Code in the Event code field.
- Write the Event Code Description in the Event code description field.
- If the Event Code must or should cause a break in the log for later data analysis, enable the Check box. Normally the Check box should be disabled.
- If necessary, write a value for the Standard value field and the Unit field for this Event Code. This is optional.
- Touch the Ok Add button.
- Touch the Change button to modify the existing record.
- Repeat items Reference to Reference until all Event Codes are created.

- Custom event codes list
- Add button
- Event code field
- Event code description field
- Check box
- Standard value field
- Unit field
- Ok Add button
- Change button
Configure Operator Sheet Automatic Signals
The information needed to produce the automatic pop up windows is stored in records. To configure these records with either PLC specified event codes or operator triggered event codes, proceed as follows:- Touch the Automatic custom input signals button, see item Reference.
- Touch the Create new sheet button to create a new operator sheet or Create a new row in the selected sheet button to add records in the selected operator sheet.
- Assign a name to the operator sheets in the Text to show in title bar field.
- Assign a delay in seconds to when the operator sheets will appear in the Delay show seconds field.

- Create new sheet button
- Create a new row in the selected sheet button
- Text to show in title bar field
- Delay show seconds field
- Select how and when this Operator sheet should be triggered:
- Option one - the operator sheet dialogue window will appear when the specified Event code occurs. Touch the Arrow button to select the occurred Event code from the pre-defined Event code window. Choose when to trigger the Event code by selecting the Check box. If necessary, set the delay time, in the Field, before the Event code can be activated again.
- Option two - the operator sheet dialogue window will appear after production start but only if the machine has been at production stop for the defined number of minutes - Production downtime
- Option three - the operator sheet dialogue window will appear when the production starts for the first time.

- Operator sheet
- Option one
- Event code window
- Arrow button
- Check box
- Field
- Option two
- Production downtime
- Option three
- To modify an Event code select it and touch the Arrow button.
- Select the required event code from the Event code list.
- Enable the Check box if the default input is “GOOD" for this Event code in the operator sheet. If it is not enabled, the operator must write the input for this Event code each time it occurs.
- To add an Event code touch the Create a new row in the selected sheet button and follow the procedure in item Reference and Reference.

- Event code
- Arrow button
- Event code list
- Check box
- Create a new row in the selected sheet button
PLMS NRG Configurator - Configure IP Settings for External Network
| Equipment Status | Power must be turn ON.
|
| Special Equipment | Keyboard with PS/2 connector |
Configuration of the IPC IP settings allows the possibility to communicate between TetraPak filling machines and a PLMS master PC using a new or existing local area network. LAN communication provides a much faster method of retrieving PLMS data and requires a much simpler hardware setup than serial communication.The PLMS Send and PLMS Receive software are no longer needed for communication between the PLMS master PC and filling machines connected to the LAN, but can be retained as a means of communication between PLMS master PCs and remote locations and offline automation. |
| Ethernet switch | Network cables | | PLMS Master PC |
Requirements
- The PLMS centre NETCOM module software must be installed on the PLMS master PC, see the PLMS centre NETCOM module software documentation for more details
- The ETH3 (external network) connector on each filling machine must be connected to the network cable 0000580010.
- The filling machines are all connected with a suitable ethernet switch using shielded pair (STP) ethernet category 5 network cable
- The PLMS master PC must be connected to the ethernet switch using shielded pair (STP) ethernet category 5 network cable.
Configuration
- Log on as an installer, see HMI and PLMS - Log on Procedure.
- From the Start menu choose Configure PLMS.
- In the PLMS NRG Configurator window touch the Hardware and network button and the IP Settings external network.

- Hardware and network button
- IP Settings external network
- The IP settings external network window appears.
- Select the LVL 5 External network with the Arrow button.
- Touch the Properties button.Note: If the IP adresses are set up outside the recomended range, the properties button will not be highlighted and selectable.

- IP settings external network window
- LVL 5 External network
- Arrow button
- Properties button
- In the properties window, perform one of the following:
- Select the Obtain IP address automatically check box, this will enable the network adaptor to retrieve an IP address from a DHCP server. If no DHCP is found, the network adaptor will randomly create an IP address
- deselect the Obtain IP address automatically check box, and use the Arrow button to enter an IP address (from 1 to 90). As the IP address is selected the network is checked to find if the address is already in useNote: Do not change the IP address field unless specifically requested by the customer: conflict with an existing network may occur. Available network are 172.16.X.3, 172.17.X.3, 172.18.X3.
- Touch the OK button to confirm the selection.

- Obtain IP address automatically check box
- Arrow button
- IP address field
- OK button
- The IP settings external network window is displayed.
- Touch the Exit button to return to the PLMS NRG Configurator window

- IP settings external network window
- Exit button
- Exit the NRG configurator.
PLMS NRG - Last Package Point Selection
| Equipment Status | Program Step |
- Press the Button.
- Press Last package point selection button.
- Select Line1.
- Select the source of the last package counting point in the line.
- If you press the Distribution equipment button you also need to select the specific distribution equipment in the displayed list.
- If you press the Photocell button, set the quantity of packages contained in one cardboard tray by using the Arrow button.
- Select Line2 and repeat this procedure from item Reference.
- Press the OK button and then the Exit button.

- Button
- Last package point selection button
- Distribution equipment button
- Photocell button
- Arrow button
- OK button
- Exit button
PLMS NRG - DE Overview
| Equipment Status | Program Step |
- Press Overview.
- Press DE status.

- Overview
- DE status
- You can see:
- To reset the counter, press Reset.

- Alarm
- Production
- Preparation
- Machine OFF
- Package
- Reset
- OK
Note: An "X" instead of icons 3, 4, 5, or 6 means the communication between the distribution equipment and TPOP was broken. The NRG Logger is affected. Correct the communication error, make sure the configured distribution equipment is switched on, and restart the TPOP.PLMS NRG - Copy Performance and Process Data
| Equipment Status | Power must be turn ON.
|
To analyse data collected by the system, the data must first be copied to an office PC. There are two possible methods:- direct communication between the filling machine and an office PC by means of the external network connection (level 5). See the PLMS Centre User Manual for the communication configuration using the Netcom module
- manual copying by means of a USB key.
This section describes how to manually copy the data only.The copied data can be analysed in an office PC utilising the PLMS Centre analysis program. For more information, see PLMS Centre User Manual.It is possible to copy performance data and process data for different kinds of analyse:- performance data files, to be analysed with the PLMS Centre analysis program using the Performance Analysis module
- process event and parameter data files, to be analysed with the PLMS Centre analysis program using the Process Analysis moduleNote: The data files are in the *.xml file format and are compressed into a *.zip folder which can be extracted with the program WinZip.
Copy Performance Data Files
- Remove the plug of a USB port in the Control panel and insert a USB memory key into the USB slot.
- Touch the PLMS setup button.
- Touch the Copy logged data button.
- Touch the Performance data button.Note: The Performance data button is pre-selected by default.

- USB port
- Control panel
- PLMS setup button
- Copy logged data button
- Performance data button
Note: The Copylog starting date button is set by default to the last downloading date. The Copylog ending date button is set by default to the date of yesterday. To download the data files from a different period of time follow the procedure .- Touch the OK button to download the performance data files.Note: Do not press the TPOP reset button on the control panel during the copying procedure, if flashing! The starting date is automatically updated every time the data log is copied.

- Copylog starting date button
- Copylog ending date button
- OK button
- TPOP reset button
Note: If the Icon is displayed, read the accompanying help text on the TPOP and perform the necessary action(s).- When the download is complete the Icon is displayed.
- If necessary, touch the Eject drive button.
- Touch the Exit button.

- Icon
- Eject drive button
- Exit button
- Icon
Copy Process Data Files
- Remove the plug of a USB port in the Control panel and insert a USB memory key into the USB slot.
- Touch the PLMS setup button.
- Touch the Copy logged data button.
- Touch the Process data button.

- USB port
- Control panel
- PLMS setup button
- Copy logged data button
- Process data button
Note: The Copylog starting date button is set by default to the last downloading date. The Copylog ending date button is set by default to the date of yesterday. To download the data files from a different period of time follow the procedure .- Touch the OK button to download the process data files.Note: Do not press the TPOP reset button on the control panel during the copying procedure, if flashing! The starting date is automatically updated every time the data log is copied.

- Copylog starting date button
- Copylog ending date button
- OK button
- TPOP reset button
Note: If the Icon is displayed, read the accompanying help text on the TPOP and perform the necessary action(s).- When the download is complete the Icon is displayed.
- If necessary, touch the Eject drive button.
- Touch the Exit button.

- Icon
- Eject drive button
- Exit button
- Icon
Change the Copylog Start/End Date
To download the data files from a different period of time follow the procedure below.- Touch the Lock button.
- Touch the Copy log start date button and select a date from the date Selection window. Note: The Arrow button change the date in step of 10 days, the Arrow button change the date in step of 1 day.
- Touch the Copy log end date button and select a date from the from the date Selection window.
- Touch the OK button to download the files.

- Lock button
- Copy log start date button
- Selection window
- Arrow button
- Arrow button
- Copy log end date button
- OK button
- Earlier date available
- Latest date available
PLMS NRG - Enter Hours
- Enter the value from the mechanical hour counter into
PLC Item: Program:HMI.HMI_PLMS_110014060_HourMeter.Note: The last digit (red in colour) on the mechanical hour counter is a decimal. - Contact your local MC running hour administrator for the default value.
- Enter the production hours into
Plc Item: Program:HMI.HMI1_PLMS_110014061_HourMeterPlc Item: Program:HMI.HMI2_PLMS_110014062_HourMeter
Note: Wait to restart the PLC at least 30 minutes after you have entered hours, or they are not registered.
TPOP AP920 - Change Push Button PCB
| Equipment Status | Power must be turn OFF.
|
Hazardous voltage.The main power supply disconnector must be switched off and secured with a lock before starting any work on the TPOP.Can shock, burn, or cause death.
- Remove the Back side and the Gasket.

- Back side
- Gasket
- Remove the Screw and the Cover on the Push button module where the PCB needs to be changed.
- Disconnect the Flat cable and the X2X cable.
- Remove the Spacer. Remove the Push button PCB.
- Replace the Push button PCB.
- Assemble in the reverse order.

- Screw
- Cover
- Push button module
- Flat cable
- X2X cable
- Spacer
- Push button PCB
TPOP APC620 - Change Battery
| Equipment Status | Power must be turn OFF.
|
Hazardous voltage.The electrical supply disconnecting device must be switched off and secured with a lock before starting any work on the TPOP.Can shock, burn, or cause death.
- Disconnect the power supply to the TPOP.
- Touch the housing or earth connection (not the power supply) in order to discharge any electrostatic charge from your body.
- Remove the black Plastic cover from the battery compartment and carefully pull out Battery using Removal strip.

- Plastic cover
- Battery
- Removal strip
- Insert the new battery with correct polarity. The battery must not be held by its edges. Insulated tweezers may also be used for inserting the battery.Note: To make the next battery change easier, be sure the removal strip is in place when inserting battery.
- Reconnect the power supply to the TPOP by plugging the power cable back in and pressing the power button.
- Set the data and time in see HMI and PLMS - Log on Procedure. Note: Lithium batteries are considered hazardous waste. Handle and dispose of used batteries in compliance with local regulations.
TPOP APC620 - Change DVD Reader
| Equipment Status | Power must be turn OFF.
|
Hazardous voltage.The main power supply disconnector must be switched off and secured with a lock before starting any work on the TPOP.Can shock, burn, or cause death.
- Disconnect the power supply to the TPOP.
- Touch the housing or ground connection (not the power supply) in order to discharge any electrostatic charge from your body.
- Open the orange Front cover. Remove the seven Kombitorx Screw.
- Remove the Side cover.

- Front cover
- Screw
- Side cover
- Simultaneously move the Slid-in slot releasing mechanism outwards. The DVD drive is pushed out a few millimetres.
- Remove the DVD drive.
- Move the Slid-in slot releasing mechanism to the start position.
- Insert the new DVD drive.
- Assemble in the reverse order.

- Slid-in slot releasing mechanism
- DVD drive
TPOP APC620 - Change Ethernet Card
| Equipment Status | Power must be turn OFF.
|
- Disconnect the power supply to the TPOP.
- Touch the housing or ground connection (not the power supply) in order to discharge any electrostatic charge from your body.
- Open the orange Front cover. Remove the nine Kombitorx Screw.
- Remove the Side cover.
- Removed the Screw and remove the Ethernet card.
- Install the new Ethernet card.
- Assemble in the reverse order.

- Front cover
- Screw
- Side cover
- Screw
- Ethernet card
TPOP APC620 - Change SDL
| Equipment Status | Power must be turn OFF.
|
- Disconnect the power supply to the TPOP.
- Touch the housing or ground connection (not the power supply) in order to discharge any electrostatic charge from your body.
- Open the orange Front cover. Remove the seven Kombitorx Screw.
- Remove the Side cover.
- Remove the two cover plate Screw and remove the SDL card from the inside.
- Install the new SDL card.
- Assemble in the reverse order.

- Front cover
- Screw
- Side cover
- Screw
- SDL card
TPOP APC620 - Change Fan Kit
| Equipment Status | Power must be turn OFF.
|
- Disconnect the power supply to the TPOP.
- Touch the housing or ground connection (not the power supply) in order to discharge any electrostatic charge from your body.
- Open the orange Front cover. Remove the nine Kombitorx Screw.
- Remove the Side cover and the Fan kit cover.

- Front cover
- Screw
- Side cover
- Fan kit cover
- Removed the Screw and remove the Ethernet 3 port.
- Simultaneously move the Slide-in slot releasing mechanism outwards to remove the Slide-in slot cover and the DVD drive.

- Screw
- Ethernet 3 port
- Slide-in slot releasing mechanism
- Slide-in slot cover
- DVD drive
- Disconnect the Fan connection cable from the circuit board.
- Remove the Kombitorx screw, remove the Fan.

- Fan connection cable
- Kombitorx screw
- Fan
Equipment damage.The fans must be inserted so that the air flows toward the inside of the housing.If the fans are not correctly installed the computer can be over heated.
Align new fans over the Fastening bolt. Feed cables through the Opening in the housing into the main board of the TPOP box. The Fan connection cable for the 40 mm fan must be placed in the Cable fastener.- Secure the Fan with the Kombitorx screw.Note: There are two arrows on the Fan that indicate the Direction of air flow and the Direction of fan rotation.

- Fan connection cable
- Kombitorx screw
- Fan
- Direction of air flow
- Direction of fan rotation
- Fastening bolt
- Opening
- 40 mm fan
- Cable fastener
- Connect the fan connection cables to the main circuit board at the following positions (fan A at position A, fan B at position B, fan C at position C).
- Assemble in the reverse order.
TPOP APC620 - Change Filter
| Equipment Status | Power must be turn OFF.
|
- Disconnect the power supply to the TPOP.
- Touch the housing or ground connection (not the power supply!) in order to discharge any electrostatic charge from your body
- Open the orange Front cover. Remove the nine Kombitorx screw.
- Remove the Side cover and the Fan kit cover.
- Place the Dust filter in the Fan kit cover and secure with the Filter clasp.
- Assemble in reverse order.

- Front cover
- Kombitorx screw
- Side cover
- Fan kit cover
- Dust filter
- Filter clasp
Change of complete APC620
If you replace a complete APC do not forget to move or order a new graphical card(A01K0007) for the TPOP panel on side 2.TPOP APC910 - Description
Note: Valid only for machines equipped with Industrial PC APC910, TP No. 90605-7102 and UK REPL APC910 3300022-0302.The APC910 (Industrial PC) is the core component of the TPOP system and consists of a computer with the TPOP and PLMS software and all the physical connections needed for communicating with the rest of the system.
- APC910
- USB port
- Ethernet port
- Ethernet port
- RS 232/485 port
- SDL/DVI port
- 24VDC power
- Ethernet port

- Cover
- CFast slot
- USB port
- Battery
TPOP APC910 - Change Battery
| Equipment Status | Power must be turn OFF.
|
Hazardous voltage.Can shock, burn, or cause death. The electrical supply disconnecting device must be switched off and secured with a lock before starting any work on the TPOP.
Any BIOS settings that have been made will remain when the battery is changed with the power turned off (the settings are stored in non-volatile EEPROM). The date and time must be reset later because this data is lost when the battery is changed.- Disconnect the TPOP power supply.
- Touch the housing or earth connection (not the power supply) in order to discharge any electrostatic charge from your body.
- Remove the Cover from the battery compartment and carefully pull out Battery using Removal strips.

- Cover
- Battery
- Removal strips
Hazardous substances.Lithium batteries are considered hazardous waste. Handle and dispose of used batteries in compliance with local regulations.
- Insert the new battery with correct polarity. The battery must not be held by its edges. Insulated tweezers may also be used for inserting the battery.Note: To make the next battery charge easier, make sure the removal strip is in place when inserting the battery.
- Reconnect the power supply to the TPOP by connecting the power cable and pressing the power button.
TPOP APC910 - Change CFast Card
| Equipment Status | Power must be turn OFF.
|
| Special Equipment | CFast 16 GB TP No. 90606-354 |
- Open the door of the electrical cabinet.
- Open the Front cover.Note: TheCFast card contains the operating system. In case of replacement, re-install the TPOP Basic and the TPOP HMI software, see .
- Open the Screw and press the Side cover to eject the CFast card.
- Install the new CFast card until it locks in position and close the Screw.

- Front cover
- Door
- Ejector button
- CFast card
TPOP APC910 - Change Solid State Drive
| Equipment Status | Power must be turn OFF.
|
| Special Equipment | Solid State Drive 60 GB TP No. 90606-355 |
Note: The Solid State Drive (SSD) contains all the data and configuration files (performance, process, operator sheet, etc).- Disconnect the TPOP power supply.
- Touch the housing or ground connection (not the power supply) in order to discharge any electrostatic charge from your body.
- Open the Front cover.
- Remove the Screw.

- Front cover
- Screw
- Remove the Side cover sliding it first toward the front and then to the side.

- Side cover
- Free the Screw fastened to the side of the Ethernet card level 5.
- Pull firmly the Screw and remove the Ethernet card level 5 from the IPC.

- Removal strip
- Solid state drive
- Slide-in the new Ethernet card level 5 making sure to align it with the Guide rail.
- Tuck the Screw back between the drive and the frame.

- Screw
- Ethernet card level 5
- Guide rail
- Put the Side cover back.

- Screw
- Side cover
TPOP APC910 - Change Auxiliary Serial Port
| Equipment Status | Power must be turn OFF.
|
| Special Equipment | RS485 Aux. COM board TP No.90606-356 |
- Disconnect the TPOP power supply.
- Touch the housing or ground connection (not the power supply) in order to discharge any electrostatic charge from your body.
- Open the Front cover of the PC.
- Remove the Screw.

- Front cover
- Screw
- Remove the Side cover sliding it first toward the front and then to the side.

- Side cover
- Remove the Screw.
- Disconnect and remove the Auxiliary serial port .
- Install the new Auxiliary serial port into the Guide rail.

- Screw
- Auxiliary serial port
- Slot
- Secure the Auxiliary serial port by the Screw.

- Screw
- Auxiliary serial port
- Put the Side cover back.

- Screw
- Side cover
TPOP APC910 - Change Ethernet Card Level 5
| Equipment Status | Power must be turn OFF.
|
- Disconnect the TPOP power supply.
- Touch the housing or ground connection (not the power supply) in order to discharge any electrostatic charge from your body.
- Open the Front cover.
- Remove the Screw.

- Front cover
- Screw
- Remove the Side cover sliding it first toward the front and then to the side.

- Side cover
- Remove the Screw and the Ethernet card level 5.
- Insert the new Ethernet card level 5 in the Guide rail and connect it to the Plug.
- Secure the Ethernet card level 5 by the Screw.

- Screw
- Ethernet card level 5
- Guide rail
- Plug
- Put the Side cover back.

- Screw
- Side cover
TPOP APC910 - Change Fan Kit
| Equipment Status | Power must be turn OFF.
|
| Special Equipment | Fan kit TP no. 90606-357 |
Hazardous voltage.The electrical supply disconnecting device must be switched off and secured with a lock before starting any work on the TPOP.Can shock, burn, or cause death.
- Disconnect the TPOP power supply.
- Touch the housing or ground connection (not the power supply) in order to discharge any electrostatic charge from your body.
- Disconnect all the connections on the APC top side.
- Loosen the Screw.
- Remove the APC and move it on a work bench.

- APC top side
- Screw
- APC
- Open and remove the orange Front cover.
- Remove the Screw and the Heat sink cover.

- Front cover
- Screw
- Heat sink cover
- Remove the Screw and disconnect the out the Fan kit cable from the mainboard.

- Screw
- Fan kit cable
- Remove the Fan kit.
- Change the Fan kit and assemble in the reverse order.

- Fan kit
Change of complete APC910
If you replace a complete APC do not forget to move or order a new graphical card(A01K0007) for the TPOP panel on side 2.Machine Settings in the PLC
| Equipment Status | Program Step Step Zero |
Preparations
Note: Make sure that you have the machine specifications and the specific values for current openings at hand.- Step the machine down to step zero and make sure that the machine is ready to step up to Air on.
- Open the Operator panel door.
- Connect a keyboard to one of the USB port on the display unit.
- Load from file according to SD Card to PLC Controller - Load from File on page SD Card to PLC Controller - Load from File.
- Press F4 on the keyboard.

- Operator panel door
- USB port
Main
- Press
Main.Note: If the screen below does not open, press anywhere on the screen and then press F4 again.
- To change the
Main settings in the items that follow, use Increase and Decrease. - To go to the second page of
Main settings, use Go to submenu. 
- Increase
- Decrease
Note: The following steps are made on the first page.- Set the
Start pos. volume on S1 and S2.Note: For machine variant ASCM, the volume is locked to Midi 300.- If the
Start pos. volume is Mini, and the actuator is assembled in the lower hole pattern of the pre-folder bracket, set Prefolder Actuator mounted in the lower holes to Yes. - If the
Start pos. volume is Mini, and the pre-folder bracket only has one hole pattern, set Prefolder Actuator mounted in the lower holes to NO.
Note: See Procedure Pre-Folder - Actuator Position for more information.
- Set the
Mailbox limit on S1 and S2 (the limit for number of blanks in the mailbox before the paper feed stops). Default value is 100. - Set
Line supervision to ON or OFF.
- Set
Cap Application Unit Installed to Yes or No. If No, continue to item Reference. - If CAU is set to Yes, make the following settings:
- Set
Cap Applicator Unit Bypass to NO. - Set
CSU left side to S1 or S2. - Set
Cap Vision System to S1, S2, S1+S2, or Off. - Set
Spruebox waste limit on S1 and S2. Default value is 11000. - Set
Cap vision height limit mm on S1 and S2. Default value is 0.8. - Set
Cap vision tilt limit deg. on S1 and S2. Default value is 1.0. - Set
Controlled Capping on S1 and S2 to YES or NO. - Set
Controlled Capping allow operator to adjust to YES or NO.
- If running Base 1000ml packages:
- Set the length of
Base 1000 depending on the top.
- Set
Production restart after DE stop to Manual, Automatic with hooters, or Automatic without hooters. - Set
Restart delay Stop s / Start s times (after queue on conveyor).
- Set
STD/US-CA version to Standard or US_CA. - Press Exit.
- Press
Save. 
- Exit
Note: The following steps are made on the second page.- Valid for: SRU version1/2 see 2.14.1 Functional DescriptionSet
Sprue remover to YES or NO. - Valid for: SRU micro see 2.14.1 Functional DescriptionSet
Sprue remover to NO. - Set
Top shape. - Set
Screw cap. - Set
Magnetic design reader to YES or NO. - Set
Sleeve stop installed to YES or NO. - Set
Cap vision system to IVC or Trispector. - Set
Top color to Standard or Translucent.Note: This option is only available if Trispector is chosen for Cap vision system.
Product Tank
- Press
Product tank.
- To change the
Product tank settings in the items that follow, use Increase and Decrease. - To go to the second page of
Product tank settings, use Go to submenu. 
- Increase
- Decrease
Note: The following steps are made on the first page.- Set
Product tank temperature alarms for S1 and S2. - Set
Fill adjust. (where to start filling). - Set
Venting (the number of venting cycles).Note: For machine variant ASCM, the number of venting cycles are locked at 10. - Make settings for
HAAD, Product pipe, Cleaning System, Quick Rinse, Gas dosing System, and Tank Cooling.Note: If HAAD is activated, the Quick Rinse option cannot be selected.
Note: The following steps are made on the second page.- Set
Agitator to YES or NO. YES means that the machine is equipped with agitators. - If
Agitator is set to YES:- Set
Agitator Speed No Production (during program steps heating, Tank Filling, and Motor Running). - Set
Agitator Speed Production (during program steps Production and End production).Note: Speed 0 rpm = agitator not running. Speedrange is 100 - 490rpm, steps of 10rpm.Note: During CIP, the agitator is not affected by the set speed.Note: Some products can be affected negatively by the speed of the agitator.
- If
ADY machine, set ADY to YES. - Make settings for
End Production Level.- The
End Production Level is activated when the level probe inside the product tank indicates low level. Set the level to a desired value on the HMI. - If not all packages get filled,
End Production Level needs to be adjusted to a larger value. - If the last packages get overfilled
End Production Level needs to be adjusted to a lower value.
- Set
ADY Product Setting according to the table below.Note: Only valid for ADY.| Setting | Description |
| 1 | Original ADY cam350 - 600 mPas |
| 2 | ADY cam600 mPas |
| 3 | New improved ADY cam350 - 600 mPas |
| 4-5 | Spare |
- Press Disinfectant.
- Press Alkali
- Press Acid.

- Disinfectant
- Alkali
- Acid
- Press Batch Rinse.
- Use
INCREASE and DECREASE to select one or two batch rinses in intermediate cleaning.
- Press Back Flush.
- Use
INCREASE and DECREASE to select one or two back flushes.
- Press Exit.
- Press
Save. 
- Batch Rinse
- Back Flush
- Exit
LFU
- Press
LFU.
If Sleeve stop installed is set to NO (in this case on both sides) then:- Enter the values according to the document that is valid for the openings on your machine.
- In the boxes A30K1281 ON/OFF and A30K1282/A30K283 box, it is possible to enter the MSP values for the cutting unit.
- Enter the
None value that is valid or press OFF in the Supervision cutter cylinder box. - Press
ON or OFF in the Detach pulse lid forming blowing box. 
- A30K1281 ON/OFF and A30K1282/A30K283 box
- Supervision cutter cylinder box
- Detach pulse lid forming blowing box
If Sleeve stop installed is set to YES (in this case both sides) then:- Press ON or OFF in the Detach pulse lid forming blowing box.

- Detach pulse lid forming blowing box
- Enter values in the Extruder frequency Low box and Extruder frequency High box.
- Enter the value for the stroke of the colour dosing cylinders in the Colour dosing box and the Colour dosing box.
- Enter the valid
None value or select OFF in the Supervision infeed mandrel box. - Repeat for S2.
- Press Exit.
- Press
Save. 
- Extruder frequency Low box
- Extruder frequency High box
- Colour dosing box
- Colour dosing box
- Supervision infeed mandrel box
- Exit
Functional Description
The Tetra Pak Multi-purpose Compact Controller (TMCC2) in the electrical cabinet is used to control and monitor the photocells that are part of the packaging material positioning system.The TMCC2 card T12K0001 is a microprocessor card that decodes the signals from the bar code detectors and converts them into a readable signal that is sent to the paper feed servo drives. | | | | | | | |
| | | | TMCC2 | | | |
| | | | | | | |
| S1 | Photocells |  | | Set and read the photocells | | | |
| | | | | | | |
| S2 | Photocells |  | | Set and read the photocells | | | |
| | | | | | | |
| | | | DeviceNet Protocol | |  | To Machine Network |
| | | | | | | |
| Terminal PC |  |  | | Communication with PLC and terminal (PC) | |  | Servo paper feed Side1/Side2 |
| | | | | | | |
| | | | | | | |
TMCC2 Card T12K0001 - Buttons and Display
The TMCC buttons, theArrow and Enter, are used to select one of several functions.- when the TMCC2 is idle the Display shows program information
- when the TMCC2 is working the Display is used as LEDs to display the operation of the TMCC2
- when a button (1,2) is pushed, the Display is used to navigate through a menu structure allowing the TMCC2 to be set up.

- Arrow
- Enter
- Display
TMCC2 Card T12K0001 - LED Display
The display, used as LED, provides the following information when the machine is in the normal Production mode.| Character | Function |
| 7 | PHD Side1 Register mark decoded |
| 6 | PHD Side2 Register mark decoded |
| 5 | Side1 Photocells Fault |
| 4 | Side2 Photocells Fault |
| 3 | Not used |
| 2 | Not used |
| 1 | Not used |
| 0 | Not used |
TMCC2 Card T12K0001 - Menu System
Pushing any button on the TMCC2 card T12K0001 enters the first level of the menu. The Arrow are then used to select an item and Enter to access the sub menus of that item.
- Arrow
- Enter
| Menu Level | |
| 1 | 2 | 3 | 4 | Description |
| S1 PHOT. | | | | |
| SPOT COL | | | Side1 Spot colour menu |
| | GREEN | | Select Green spot colour |
| | BLUE | | Select Blue spot colour |
| | RED | | Select Red spot colour |
| | BACK | | Exit from Spot colour menu |
| DYN. TH. | | | Side1 Dynamic Threshold menu |
| | PTH= xxh | | Change dynamic threshold setting |
| CALIB. | | | Side1 Manual calibration menu |
| | USE CAL. | | Use manual calibration |
| | RUN CAL. | | Run manual calibration |
| | BACK | | Exit manual calibration menu |
| PULSE | | | Side1 Pulse length menu |
| | PL= xx | | Change Side1 pulse length |
| BACK | | | Exit from S1 Photocells menu |
| S2 PHOT. | | | | |
| SPOT COL | | | Side2 Spot colour menu |
| | GREEN | | Select Green spot colour |
| | BLUE | | Select Blue spot colour |
| | RED | | Select Red spot colour |
| | BACK | | Exit from Spot colour menu |
| DYN. TH. | | | Side2 Dynamic Threshold menu |
| | PTH= xxh | | Change dynamic threshold setting |
| CALIB. | | | Side2 Manual calibration menu |
| | USE CAL. | | Use manual calibration |
| | RUN CAL. | | Run manual calibration |
| | BACK | | Exit manual calibration menu |
| PULSE | | | Side2 Pulse length menu |
| | PL= xx | | Change Side2 pulse length |
| BACK | | | Exit from S2 Photocells menu |
| MAC ID | | | | MAC ID Menu |
| MACID=xx | | | Change Node MAC ID (default is 56) |
| BACK | | | | Exit from menu structure |
TMCC2 Controller - Set Photocell Colour
| Equipment Status | Program Step step zero |
By default, the photocell produces a green light spot. For most packaging materials this is the correct setting and no further adjustment will be required.If a bar code reading errors occur, the colour of the light spot can be changed to match the colour of the bar code. This is done through the menu on the TMCC2 card or on the TPOP (see OM). See the table below for the recommended colours.| Bar Code Colour | Photocell Colour |
| Black | Green, Red or Blue |
| Blue | Green or Red |
| Light blue/Cyan | Red |
| Green | Red or Blue |
| Yellow | Blue |
| Red | Green or Blue |
| Magenta | Green |
Set Photocell Spot Colour on the TPOP
The machine has to be in AIR ON to TANK FILLING.- Press
Manoeuvre window. - Press
Carton section.
- Press
Barcode photocell. The button turns blue.
- Press
Enable increase/decrease to activate the Up and Down arrows.
- Use the
Up and Down buttons to select the bar code colour and choose between the photocell beam colour.See the table for the recommended colours.Note: If a barcode reading error still occurs, set the dynamic threshold. See Set Photocell Dynamic Threshold below, or call a technician.| Bar Code Colour | Photocell Colour |
| Black | Green, Red or Blue |
| Blue | Green or Red |
| Light Blue/Cyan | Red |
| Green | Red or Blue |
| Yellow | Blue |
| Red | Green or Blue |
| Magenta | Green |
Set Photocell Spot Colour Manually
- Make sure that the Switch on the Photocell unit is set to the position Run.
- Press any of the Arrow button or the Enter button on the TMCC2 card.
- Use the Arrow button to select S1 PHOT. or S2 PHOT. and press the Enter button.
- Use the Arrow button to select SPOT COL and press the Enter button.
- Use the Arrow button to select a colour that suits the current packaging material press the Enter button.
- Use the Arrow button to select Back and press the Enter button in each menu step to exit the menu.

- Switch
- Photocell unit
- Arrow button
- Enter button
- If errors continue to occur after the photocells colour setting, set the photocell sensitivity, see TMCC2 - Set Photocell Sensitivity, page TMCC2 - Set Photocell Sensitivity.
TMCC2 - Set Photocell Sensitivity
| Equipment Status | Program Step |
Set Photocell Sensitivity Manually
The sensitivity of the photocells can be adjusted if errors continue to occur after the manual setting of the photocells. The photocells sensitivity can be set to a value ranging from 32 to 242, the standard setting is 48. A high value will result in a lower sensitivity of the photocells.- Press any of the Enter button or the Arrow button on the TMCC2 card.
- Use the Enter button to select S1 PHOT. or S2 PHOT. and press the Arrow button.
- Use the Enter button to select DYN.TH. and press the Arrow button.
- Use the Enter button to select a value between 32 to 242 and press the Arrow button.
- Exit the menu on the TMCC2.
- If errors continue to occur after the photocells colour setting, the dynamic threshold setting and alignment is accurate set the photocells manually, see Procedure TMCC2 - Set Photocells KT15 Manually for KT15 photocells, or TMCC2 - Set Photocells KTx Manually for KTx photocells..

- Arrow button
- Enter button
Set Photocell Sensitivity on the TPOP
The sensitivity of the photocells can be adjusted if errors continue to occur after the manual setting of the photocells. The photocells sensitivity can be set to a number ranging from 32 to 242. The standard setting is 48. Setting a high value will result in a lower sensitivity of the photocells.The machine has to be in Air On to Tank Filling.- Press
Manoeuvre window. - Press
Carton section.
- Press
Contrast.
- Press
Enable increase/decrease to activate the Up and Down arrows.
- Use the
Increase and Decrease buttons to change the contrast value.Note: A high threshold value makes the photocells less sensitive.Note: If errors still occur, call a technician.
TMCC2 - Set Photocells KT15 Manually
| Equipment Status | Program Step |
- Press any of the Arrow button or the Enter button on the TMCC2 card.
- Use theArrow button to select S1 PHOT. or S2 PHOT. and press the Enter button.
- Use theArrow button to select CALIB. and press the Enter button.
- Use theArrow button to select RUN CAL. and press the Enter button. This sets the photocells to teaching mode.

- Arrow button
- Enter button
- Make sure that the Switch on the Photocell unit is set to the position Q1.
- Move the packaging material until the photocell spot is focused on a white part of the packaging material.
- Push and hold Teach.
- Move the packaging material until the complete bar code has passed in front of the photocell and then release Teach. The photocell automatically calibrates itself.
- If the LED blinks 5 seconds the teach in procedure was successful.Note: TheON LED is lit when power is supplied to the photocell. The Q/OK LED is lit when the photocell spot is focused on a dark area of the packaging material.
- Repeat item Reference to Reference for the other photocell.
- Use theArrow button to select Back and pressEnter button in each menu step to exit the menu.
- Restore the Switch on the Photocell unit to the position Run.
- If errors continue to occur after the manual setting, see Procedure TMCC2 - Set Photocell Sensitivity on page TMCC2 - Set Photocell Sensitivity.

- Switch
- Photocell unit
- Teach
- ON LED
- Q/OK LED
TMCC2 - Set Photocells KTx Manually
- Press any of the Arrow button or the Enter button on the TMCC2 card.
- Use the Arrow button to select S1 PHOT. or S2 Phot and press the Enter button.
- Use the Arrow button to select CALIB and press the Enter button.
- Use the Arrow button to select RUN CAL and press the Enter button. The display on the TMCC2 is now showing waiting. This sets the photocells to access the teaching mode.

- Arrow button
- Enter button
KTx Bar Code Readers- Adjust the Screw and the Guide finger on the side of the two photocells to prevent the package material to wobble up and down.
- Release the feeder wheel by pulling the knob and turning the Handle down.

- Screw
- Guide finger
- Handle
- Move the packaging material until the photocell spot is focused on a white part of the packaging material before the bar code.
- Push the Set button so the display shows tch Push the set button again so the display show dyn (if necessary change to dyn with + or - buttons). Push the set button again to get the running bars on the display. Now the colour of the light beam changes to white, and the photocell is prepared for calibrationNote: Both photocells can be calibrated at the same time.

- Set button
- Move the packaging material until the complete bar code has passed in front of the photocell and then push the Set button. The photocell automatically calibrates itself. The display shows 100 (%) for some seconds if the calibration was successful. If the display shows Err, repeat Reference to Reference again.

- Set button
TMCC2 Card- After photocell calibration, press the ENTER button on the TMCC2 card. The display shows DONE.
- Repeat item Reference to Reference for the other photocells if necessary.
- Use the ARROW buttons to select USE CAL and press ENTER button.
- Use the ARROW buttons to select BACK and press ENTER button in each menu step to exit all menus. The TMCC2 shows Prg. No xxxxxxx-xxxx on the display.
- Restore the feeder wheel release handle to its locked position.
- If bar cone error alarm continues to occur on the TPOP after the manual setting, see TMCC2 - Set Photocell Sensitivity in MM.
TMCC2 Controller - Set Communication
| Equipment Status | Program Step |
| Special Equipment | RS 232-C Communication Cable AT Compatible PC with CD Drive |
- Connect the TMCC2 to a PC with the Connection cable. It may be necessary to exit and shut down RSLinx to establish connection. The connections required are:Note: Do not connect any other pin.
| PC 9-pin, female | TMCC2 9-pin, male |
| 2 | 3 |
| 3 | 2 |
| 5 | 5 |
- Start up the program to use, for example Windows hyperterminal program.
- Type a name for the file.
- Select the correct COM port.
- Set up the program as follows:
| Baud rate | 9600 |
| Bits | 8 |
| Parity | None |
| Stop bits | 1 |
| Flow control | None |

- Connection cable
TMCC2 Controller - Load Program
| Equipment Status | Program Step |
| Special Equipment | RS 232-C Communication Cable AT Compatible PC with CD Drive |
- Configure a PC to be used as a hyperterminal and connect it to the TMCC2, see TMCC2 Controller - Set Communication.
- Start the hyperterminal file 2942001-xxxx.
- Type
Stop and press Enter. - Insert the TMCC CD into the CD drive of the PC.
- Type
E flash and press Enter. - When the TMCC2 prompt appears (
TMCC2->), type D and press Enter. - Select the menu
Transfer and the menu item Send text file. - Change
Files of type to all files (*.*) - Browse to the TMCC CD, locate and download the file TMCC PHD.mhx.
- The download progress is displayed with dots on the screen, when the download is finished the text
Download OK appears on the screen. - At the TMCC2 prompt type
Run and press Enter.
- Type
S to verify the downloaded programs status.
TMCC2 Controller - Display Report
| Equipment Status | Program Step |
| Special Equipment | TMCC2 Communication Cable AT Compatible PC |
- Configure a PC to be used as Windows terminal and connect it to the TMCC2, see TMCC2 Controller - Set Communication.
- Enter the commands and parameters into the PHD program via the keyboard and execute them by pressing Enter. The functions described below are available:
| H | Help Menu: displays the commands available. |
| L | Description of the function of the display on the front panel. |
| S | Shows the program version and if there is a failure of the photocells. |
| STOP | Stops the application program and enters the firmware of the TMCC2. This can be used when the application should be upgraded to a newer one, or in case a reset is necessary. |
| Y | Displays a detailed status of the photocells for test and service purposes: |
| Commands OK: | Total number of commands executed by the photocells |
| Commands failed: | Total number of commands failed |
| Barcode decoded: | Total number of barcodes decoded by the TMCC2 |
| Dynamic Threshold: | Photocell threshold |
| Light Spot: | Colour of the light spot used by the photocells |
| Output: | Logic of the photocell outputs (Light/Dark switching) |
| Photoswitch Working Hours | Number of hours that every LED of the photocell has been working |
| Photocell Software ver. / S.N.: | Software version of the photocell firmware and serial number |
| Sx,CFG=y | Changes the side x photocell configuration. The y value can be G (green), R (red), B (blue), or T (last taught value). |
| Sx,PTH=y | Changes the dynamic threshold value of the photocells. The value is a decimal value ranging from 32 to 242 stored in the EEPROM. High dynamic threshold values result in a lower photocell sensitivity. |
| Sx,PLS=t | Changes side x output puls length. The value t is a decimal value ranging from 5 to 255 ms. |
| Lx,D | Disables the latch x function. |
| Lx,R,t | Enables the latch x function to be triggered on the input rising edge. The value t is a decimal value ranging from 5 to 255 ms, it represents the output puls length. |
| Lx,F,t | Enables the latch x function to be triggered on the input falling edge. The value t is a decimal value ranging from 5 to 255 ms, it represents the output puls length. |
| V | Shows program number and version |
| Ax | If x is 1, a diagnostic function is activated on Side1 decoder. The printed value gives an indication of the photocells alignment. If this value is greater than 1, it means that the Data signal (3 bar) is coming to late. If this value is less than 1 it means that the Clock signal (4 bar) is coming to late. The value should be as close as possible to 1. If x is 0, the diagnostic function is disabled. This function automatically disables after 1000 tests. |
| Dx | If x is 1, a diagnostic function is activated on Side2 decoder. The printed value gives an indication of the photocells alignment. If this value is greater than 1, it means that the Data signal (3 bar) is coming to late. If this value is less than 1 it means that the Clock signal (4 bar) is coming to late. The value should be as close as possible to 1. If x is 0, the diagnostic function is disabled. This function automatically disables after 1000 tests. |
| ECLEAR | Restores default values into the EEPROM. |
TMCC2 - Fault Codes
When the communication with the photocells fails an error message is displayed as follows:| Side1 3 Bars Ph. Failure | Photocells Fault |
| Side1 4 Bars Ph. Failure | Photocells Fault |
| Side1 3 Bars and Side1 4 Bars Ph. Failure | Photocells Fault |
| Side2 3 Bars Ph. Failure | Photocells Fault |
| Side2 3 Bars and Side1 3 Bars Ph. failure | Photocells Fault |
| Side2 3 Bars and Side1 4 Bars Ph. failure | Photocells Fault |
| Side2 3 Bars, Side1 3 Bars and Side1 4 Bars Ph. failure | Photocells Fault |
| Side2 4 Bars Ph. failure | Photocells Fault |
| Side2 4 Bars and Side1 3 Bars Ph. failure | Photocells Fault |
| Side2 4 Bars and Side1 4 Bars Ph. failure | Photocells Fault |
| Side2 4 Bars, Side1 3 Bars and Side1 4 Bars Ph. failure | Photocells Fault |
| Side2 3 Bars and Side2 4 Bars Ph. failure | Photocells Fault |
| Side2 3 Bars, Side2 4 Bars and Side1 3 Bars Ph. failure | Photocells Fault |
| Side2 3 Bars, Side2 4 Bars and Side1 4 Bars Ph. failure | Photocells Fault |
| All photocells failure | Photocells Fault |
| On Line, but no connections in the established state | DeviceNet Comm. Fault |
| One or more I/O connections are in Timed-Out state | DeviceNet Comm. Fault |
| PHD program incapable of communicating on the network | DeviceNet Comm. Fault |
| PHD not On Line | DeviceNet Comm. Fault |
Functional Description
The purpose of the vision system is to detect tilted screw caps (the torque supervision in the CAU will guarantee that the screw caps are properly tightened). The packages are scanned while passing the vision system on the conveyer. The system uses a laser beam and a camera to scan the packages. The reliability of the system will increase if the packages pass the vision system with a smooth movement.Package scanning is activated by the photocell. If a screw cap is tilted, the pusher will push the package of the conveyer. If the package volume is changed the camera will automatically adjust to the new package height. The vision system uses the Ethernet cable to communicate with the PLC. Information about package volume are sent and PLMS data and alarms are being transmitted to the PLC.The vision unit will make a reading when the photocell is activated. To read the next package the photocell must first be deactivated. Because of this there must be space between the packages. Normally there is space between the packages, but if the packages twist on the conveyer they will block the signal from the photocell and the reading will not be performed.The Backside of the Camera

- Ethernet connected light (green)
- Communication in progress light (blinking yellow)
- Power on light (green)
- Function light
- Ethernet connection
- Power connection
- Not used (sealed)
Camera Unit IP - Set
| Equipment Status | Air must be turn ON. Program Step |
| Special Equipment | Computer with IVC Studio installed. |
- IVC Studio must be installed according to:
- Make sure that the Ethernet cables for the camera and the computer is connected to the Ethernet switch A01K0003 in the main electrical cabinet.
- Change IP address according to:
- Deactivate the firewall in your computer.
- Start IVC Studio (version according to the software CD).
- Click
Configuration under Options.
- Select Ethernet device.
- Click Change IP.

- Ethernet device
- Local IP
- Change IP
- Select theLocal IP 10.255.1.53 from the list.
- Click Save IP.
- Click Ethernet Device Configuration.

- Local IP
- Save IP
- Ethernet Device Configuration
- Select the camera that should be set from the Device list.Note: Temporarily unplug one of the cameras if you are uncertain witch one to select.
- Configure the Settings according to table:
| Side1 | Side2 |
| IP | 10.255.1.24 | 10.255.1.25 |
| Netmask | 255.255.0.0 | 255.255.0.0 |
| Gateway | 0.0.0.0 | 0.0.0.0 |
| DNS | 0.0.0.0 | 0.0.0.0 |
| WINS | 0.0.0.0 | 0.0.0.0 |
| TimeServer | 0.0.0.0 | 0.0.0.0 |
| DHCP | 0 | 0 |
| DHCP Wait Save | 5 | 5 |
| DHCP IP Auto Configuratic | 0 | 0 |
| ID | 1 | 2 |
| Net Bios | | |
| FTP Server Enable | 0 | 0 |
| HTTP Server Enabled | 1 | 1 |
| Communication Enabled | 1 | 1 |
| Dead Space Threshold | 50 | 50 |
| Image Banks | 4 | 4 |
| Profile Banks | 1 | 1 |

- Device list
- Settings
- ClickUpdate and wait for update complete. Confirm on the popup window with
OK. - Click Reset device. Confirm on the popup window with
Yes. - ClickExit and then the setting is complete.
- Activate the firewall in your computer.

- Update
- Reset device
- Exit
Firmware and FPGA - Install
| Equipment Status | Air must be turn ON.
|
| Special Equipment | Computer with IVC Studio installed. |
- IVC Studio must be installed according to:
- Make sure that the camera unit IP is correctly set according to:
- Make sure that the Ethernet cable for the camera and the computer is connected to the Ethernet switch A01K0003 in the main electrical cabinet.
- Change IP address according to:
- Deactivate the firewall in your computer.
- Start IVC Camera Updater.
- SelectLocal IP 10.255.1.53.
- Select camera unit by ID.
- Select Version according to the software CD.
- Click Update camera.Note: If the pop up windowIVC Camera Updater appears, click Yes.
- Wait for the message Update is completed.
- Click
Close, exit and then the installation is complete. - Repeat from item Reference for the other side of the machine.
- Activate the firewall in your computer.

- Local IP
- ID
- Version
- Update camera
- IVC Camera Updater
Camera Unit Program and Table - Install
| Equipment Status | Air must be turn ON.
|
| Special Equipment | Computer with IVC Studio installed. Machine Software CD. |
- Make sure that the Firmware and FPGA is installed according to:
- Make sure that the Ethernet cables for the camera and the computer is connected to the Ethernet switch A01K0003 in the main electrical cabinet.
- Change IP address according to:
- Deactivate the firewall in your computer.
- Start IVC Studio (version according to the software CD).
- Click
Configuration under Options.
- Select Ethernet device.
- If theLocal IP is not 10.255.1.53 click Change IP.

- Ethernet device
- Local IP
- Change IP
- Select theLocal IP 10.255.1.53 from the list.
- ClickSave IP and click Ok.

- Local IP
- Save IP
- Ok
- Click
Open Product in the File menu. - Open the file
TT3VisionSystem.prc on the Machine Software CD.
- Select Devices.
- Mark the Check box.
- Right click on the camera you are installing and click
Stop Program. - Right click on the camera you are installing and click Select Program.

- Devices
- Check box
- Select Program
- Select Lid Integrity.
- Click Ok.

- Lid Integrity
- Ok
- Right click on the camera you are installing and click
Select Table.
- Select Lid Integrity.
- Click OK.

- Lid Integrity
- OK
- Right click on the camera you are installing and click:
Flash/Write program in flash.
- Select row
0 and click Save. - Confirm with
Yes in the pop up window, wait for the pop up window that reads Operation successfully executed and click OK.
- Right click on the camera you are installing and click
Start Program.
Note: When the text RUN appears in the status field the installation is complete.- Repeat items Reference to Reference for the other side of the machine.
- Activate the firewall in your computer.
IVC Studio - Install
| Equipment Status | Air must be turn ON.
|
| Special Equipment | Computer with administrator rights. Machine Software CD. |
- Insert the Machine Software CD.
- Open the IVC Studio program folder.
- Double click on the file Setup.exe to start the installation.
- Click
Next to proceed with the installation.
- Enter theSerial number found in the file Serial.txt on the Machine Software CD.Note: The default serial number is not correct. The Serial number must be according to machine software CD.
- Click Next.
- Follow the steps in the installation wizard to complete the installation.

- Serial number
- Next
Vision Unit - Record IVC Studio Live Device
| Equipment Status | Program Step Production |
| Special Equipment | PC |
The IVC Studio Live Device is a feature for monitoring the cap neck measurement and the general camera function.- Right click on the actual camera and click:
- Run a few packages through the vision unit to collect some data.

- Image top view
- Execution time
- Cap angle
- Cap height
- Last step with error
- Last error code
- Volume sent from PLC
- Run camera program
- Stop camera program
- Exit Live Device
Vision Unit - Cycle Power
| Equipment Status | Air must be turn ON.
|
During the vision system initiation the setting for communication will be performed twice. If the PLC communication is ON during this procedure problems will occur. The PLC communication must therefore be switched OFF during the procedure- Turn OFF the vision system according to:
- Switch OFF the power to the vision system.
- Wait for the alarm on the TPOP to occur (approximately 20 seconds).
- Switch ON the power to the vision system.
- Wait 1 to 2 minutes for the vision system to initiate to avoid communication problems.
- Press reset on the TPOP to reset the alarm.
- Turn ON the vision system according to:
Firmware Downgrade - Rebuild
| Equipment Status | Air must be turn ON.
|
| Special Equipment | Computer with IVCStudio installed. |
Camera Connected
Note: Perform instructions if it is possible to connect to the camera.- Open TCP/IPv4 Settings.

- TCP/IPv4 Settings
- Choose advanced Settings.

- advanced Settings
- Choose Default Settings.

- Default Settings
- Open Windows Firewall Settings.
- Choose Change settings.
- Choose Allow Another program....

- Firewall Settings
- Change settings
- Allow Another program...
- Allow IVCStudio and ICSCamera Updater and their Features to communicate through Windows Firewall.


- IVCStudio and ICSCamera Updater
- Features
- Save the calibration files from the camera: activate FTPServerenabled by setting it to FTP Server Enabled in IVCStudio\Options\Configuration\Ethernet Devices. See procedure Camera Unit IP - Set.Note: Create backup to save the calibration files in case the firmware downgrade fails and the internal flash memory goes corrupt.

- FTP Server Enabled
- Open a new folder in Windows and type the valid IP Address for the camera.

- IP Address
- Wait until the popup window appears.
- Type in: Username: anonymous and Password: guest.
- Copy the files CalibDataX.ivc and CalibDataZ.ivc to your computer.
- Downgrade the firmware to 3.1SR1 and load table according to procedure Firmware and FPGA - Install.Note: If this step makes the internal flash memory corrupt, follow instructions in procedure .
- Load program according to procedure Camera Unit Program and Table - Install.
Firmware Downgrade - Rebuilding Troubleshooting
| Equipment Status | Air must be turn ON.
|
| Special Equipment | Computer with IVCStudio installed. |
Camera Not Connected
Note: Perform instructions if it is not possible to connect to the camera.Note: If the function light on the backside of camera is flashing GREEN - RED - YELLOW, it means that the flash memory has become corrupt. At his point the camera can not be found in IVCStudio.- Turn the camera power off.
- Connect 24V to the Pin 8 in the RS485 on the camera while turning on the power.Note: Repeat this step until Function light stops flashing GREEN - RED - YELLOW. Once flashing stops, the flash memory is re-formatted.

- Pin 8
- RS485
- Function light
- Check if camera is visible in IVCStudio.
- Perform steps according to procedure Camera Unit IP - Set.
- Perform steps according to procedure Firmware and FPGA - Install.Note: Note! If the firmware downgrade fails to run IVCStudio 3.3 Camera Updater Tool, update the camera to the same firmware it used to have when delivered (3.3SRx). After update, downgrade it to 3.1SR1 using IVCStudio 3.3 Camera Updater Tool.Note: If the function light indicates RED after the camera is configured and in status RUN, it may indicate that the calibration files are missing.
- Perform steps Firmware Downgrade - Rebuild to Firmware Downgrade - Rebuild, in procedure Firmware Downgrade - Rebuild.
- Copy files CalibDataX.ivc and CalibDataZ.ivc to the camera.Note: Calibration files are available on SICK. In case the calibration files are lost, create a ticket containing the serial-number of the camera on https://supportportal.sick.com.Note: Calibration files are unique for each camera ID/serial number. However, it is possible to run the camera with calibration files from another camera but it is not recommended.
- Load program according to Camera Unit Program and Table - Install.
TriSpector Camera
TT3 2000Functional Description
The purpose of the vision system is to detect tilted screw caps (the torque supervision in the CAU guarantees that the screw caps are correctly tightened). The packages are scanned while passing the vision system on the conveyor. The system uses a laser beam and a camera to scan the packages. If the packages pass the vision system with a smooth movement, the reliability of the system increases.Package scanning is activated by the photocell. If a screw cap is not correctly attached, the pusher pushes the package off the conveyor. The vision system uses the Ethernet cable to communicate with the PLC. Information about package volume is sent and PLMS data and alarms are being transmitted to the PLC.The vision unit makes a reading when the photocell is activated. To read the next package, the photocell must first be deactivated. Because of this, there must be space between the packages. Normally there is space between the packages, but if the packages twist on the conveyor, they block the signal from the photocell and the reading is not performed.Camera - Install AppManager
TT3 2000 | Equipment Status | Power must be turn ON.
|
| Special Equipment | Ethernet cable |
- Download the latest camera software from PIV.
- Find the CAP VISION APPMANAGER folder on the software media and extract the compressed folder.
- Install the AppManager: SICK_AppManager****.exe.
Camera - Load Firmware
TT3 2000 | Equipment Status | Power must be turn ON.
|
| Special Equipment | Ethernet cable |
- Download the latest camera software from PIV.
- Find the CAP VISION TRISPECTOR firmware folder on the software media and extract the compressed folder.
- Start the appmanager.
- Press the Firmware tab and the Add firmware button.
- Browse to the camera Firmware on the PC in the Firmware folder.
- Press the Open button. The firmware shows up in the list.

- Firmware folder
Firmware tabAdd firmware button- Firmware
Open button
- Select the Firmware in the list on the right and the Connected camera in the list of devices on the left.
- Press the Install button.
- Confirm the installation by pressing the OK button in the dialogue box.
- When the installation is complete, press the
OK button in the dialogue box. 
- Firmware
- Connected camera
Install buttonOK button
Camera - Load Application
TT3 2000 | Equipment Status | Power must be turn ON.
|
| Special Equipment | Ethernet cable |
- Download the latest camera software from PIV.
- Find the CAP VISION TRISPECTOR SW folder on the software media and extract the compressed folder.
- Start the AppManager.
- Select the Camera in the upper left field.
- Select all Installed applications in the lower left field.
- Press the Delete all button.
- Confirm with the OK button.

- Camera
Delete all button- Installed applications
OK button
- Press the Local Packages tab.
- Press the Add button.
- Browse for the Camera application in the CAP VISION TRISPECTOR SW folder.
- Press the Open button. The application is displayed in the list on the right.

- CAP VISION TRISPECTOR SW folder
Local Packages tabAdd button- Camera application
Open button
- Select the Application.
- Select the Connected camera in the list of devices.
- Press the Install button. Confirm the installation by pressing the
OK button in the dialogue box. - When the installation is complete, press the
OK button in the dialogue box. 
- Connected camera
Install button- Application
- Check if the Application are visible in the field.
- To complete the software installation, restart the camera.

- Application
Description

- Connector Gigabit Ethernet (Gig E)
- Connector Power I/O (thread outside)
- LED On
- LED Link/Data
- LED Result
- LED Laser
| Led Indicators |
| Name | Colour | Function |
| LED On | Green | Power on |
| LED Link/Data | Green | Gigabit Ethernet (Gig E)Link: LED onActivity: LED blink |
| LED Result | Green | Programmable |
| Red | Programmable |
| Blue | Programmable |
| No light | Programmable |
| LED Laser | Green | Laser on |
Note: The LED Link/Data does not work with 100 Mbps switches in firmware version 4.2.0.NAT Router - Set
TT/3 | Equipment Status | Power must be turn ON.
|
- Set up the PC's IP address to 192.168.1.248 and the subnet mask to 255.255.255.0.
- Connect a cable from your laptop to the LAN Input on the router.
- Open a web browser.
- Make sure that no proxy settings are active. In Microsoft Internet Explorer, select .
- Select the Connections tab and press the LAN settings button and clear the check box Use automatic configuration scrips check box.

Connections tabLAN settings buttonUse automatic configuration scrips check box
- Enter address https://192.168.1.1.Note: If you can not access the IP address. Preform a factory reset according to the on page .
- Login using the following:
- User Name = admin
- Password = mGuard
- Go to .
- Browse the software CD and extract the compressed configuration file onto the laptop.Note: The configuration file has extension .atv
- Click the Browse button and select the configuration file.
- Click the Upload button.

Browse buttonUpload button
- Press the Restore button on the same line as the configuration profile uploaded.Note: The entry for the configuration profile being used is preceded by an Active symbol.
- Configure the NAT router for your machine according to NAT Router - Configuration.

- Active symbol
Restore button
NAT Router - Configuration
TT/3 | Equipment Status | Power must be turn ON.
|
If the NAT router is set according to NAT Router - Set, the window below will appear showing the new configuration.Repeat step a) to f) in NAT Router - Set with the new IP adress 10.255.1.248 in step a) and the new URL 10.255.1.254 in step f).Select Network and then Interfaces. In the External Networks area, set the Adress according to the customer network:
- Adress
This is the default setting for the NAT router. Configure according to the image below.NAT Router - TPOP Settings
TT/3 | Equipment Status | Power must be turn ON.
|
For PLMS to work properly the following has to be done on the TPOP.- Go to the filling machine and logon with the Administrator Account.
- Open explorer and locate the file as below.
- Open it with notepad.
- Enter the red marked line referring to the engineering station where the files are stored.Note: This is only an example. IP address and name resolution of your server must be used.
- Save the file and close it.
- Open the network settings on the TPOP and select properties.
- For level 7 network. Enter default gateway as in the example below.
NAT Router - Troubleshoot
TT/3 | Equipment Status | Power must be turn ON.
|
There are seven status indicators on the NAT router and one reset button.
- Reset button
- P1 LED
- STAT LED
- MOD LED
- P2 LED
- ERR LED
- FAULT LED
- INFO LED
| LED | Colour | State | Meaning |
| P1 LED | Green | On | Power supply 1 is active. |
| P2 LED | Green | Off | Redundant supply not provided. |
| STAT LED | Green | Flashing | Heartbeat. The device is correctly connected and operating. |
| ERR LED | Red | Flashing | System error. Restart the device:- Press the Reset button (for 1.5 seconds).
- Alternatively, briefly disconnect the device power supply and then connect it again.
Start the recovery procedure if the error continues to occur. See Recovery Procedure on page Recovery Procedure. |
| STAT LED + ERR LED | Green and red | Flashing | Boot process. When the device has just been connected to the power supply. After a few seconds, this LED changes to the heartbeat state. |
| FAULT LED | Red | On | The alarm output is open due to an error at “low” signal. (The alarm output is interrupted during a restart.) |
| MOD LED | Green | Off | Connection via modem not provided. |
| INFO LED | Green | Off | VPN connection not provided. |
| LAN & WAN LEDs | Green | On | The LAN/WAN LEDs are located in the LAN/WAN sockets (10/100 and duplex LED).Ethernet status: Shows the status of the LAN/WAN ports. As soon as the device is connected to the relevant network, the LEDs light up continuously to indicate the presence of a network connection over LAN or WAN. The LEDs go out briefly when data packets are being transferred. |
Recovery Procedure
- Press the Reset button slowly six times.
- After approximately 2 seconds, the STAT LED lights up green.
- Press the Reset button again slowly six times.
- If successful, the STAT LED lights up green. The device will reboot after two seconds and switch to Stealth mode.It can then be accessed again at the following address: https://192.168.1.1/Note: If unsuccessful, the ERR LED lights up red.
- Set the NAT router according to Procedure NAT Router - Set on page NAT Router - Set.

- Reset button
- STAT LED
- ERR LED
Description
This chapter contains the maintenance procedures for the extra equipment Tetra Top Cleaning Unit (TTCU).TTCU - Check Emergency Stop
| Equipment Status | Program Step |
Check the emergency stop push-button on the TTCU, see chapter Safety Precautions for location of the emergency stop push-button.- Run hygiene chamber cleaning, for example an alkali cleaning, according to the Operation Manual.
- While cleaning of the hygiene chamber is performed, activate the emergency stop push-button on the TTCU.
- Confirm that the TTCU stops and that the red warning lamp is lit with a flashing light.
- Confirm that the filling machine drops to the program step AIR ON, that the yellow warning lamp is lit with a flashing light, and that the alarm appears on the TPOP.
- If the TTCU does not stop, replace the TTCU emergency stop push-button and perform a new check.
- Acknowledge the alarm on the TPOP.
- Reset the emergency stop push-button and push the reset,
- the red warning lamp goes out.
- the warning symbol on the TPOP and the yellow warning lamp on the filling machine goes out.
- Step up the machine and the hygiene chamber cleaning program continues.
TTCU - Check Pipes
| Equipment Status | Program Step |
Hot parts.Before service, make sure that the pipes are cool before performing this procedure.Pipes and components in the Tetra Top Cleaning Unit can cause burn damages.
- Make sure that all clamps are tightened.
- During cleaning or disinfection of the hygiene chamber make sure that the connection points are not leaking.
- If necessary, change the gaskets inside of the Clamp, at all the connection points.
- Make sure that the Flow meter is not leaking.

- Clamp
- Flow meter
TTCU - Set Disinfectant Dosing Factor Depending on Chemical Type
| Equipment Status | Power must be turn OFF.
|
| Consumables | Disinfectant |
Laboratory Preparations
Note: Disinfectant dosage settings must be done each time a new disinfectant dosage pump is installed, and each time new chemical products are used for hygiene chamber disinfection.- Make sure that the Disinfectant pump is calibrated, see Procedure Chemical Pumps - Calibrate Disinfectant Dosage Pump on page Chemical Pumps - Calibrate Disinfectant Dosage Pump.
Hazardous substance.Use protective safety equipment: safety glasses, protective gloves, apron, and respirator with gas vapour filters when performing this procedure.The procedure below involves a substance that is hazardous to your health.
Prepare the carriage with the a container containing the preferred disinfectant according to the table in Section Chemicals for Cleaning and Disinfection on page Chemicals for Cleaning and Disinfection.
- Disinfectant pump
Set Machine Configuration
- Set the configuration according to Procedure Machine Settings in the PLC, sub procedure Machine Settings in the PLC on page Machine Settings in the PLC.
- Use
Increase and Decrease to set the TTCU Disinfectant dosage factor. - Set the dosing factor depending on chemical type according to the table for the specific pump that is installed in the TTCU.Values for pump 90600-3280:
| Chemical Type | Valid for: Hygiene level XH | Valid for: Hygiene level AD |
| P3-Oxonia | 13 | 9 |
| P3-Oxonia 150 | 25 | 25 |
| Divosan active VT5 | 14 | 10 |
| Divosan forte VT6 | 28 | 28 |
Values for pump 90605-3022:| Chemical Type | Valid for: Hygiene level XH | Valid for: Hygiene level AD |
| P3-Oxonia | 8 | 5.6 |
| P3-Oxonia 150 | 15.6 | 15.6 |
| Divosan active VT5 | 8.7 | 6.2 |
| Divosan forte VT6 | 17.4 | 17.4 |
- Check the disinfection solution according to Procedure Tank Unit - Check Solution Concentration on page Tank Unit - Check Solution Concentration.The solution must have a concentration of A. If necessary, adjust the disinfectant dosage, see below.
| Valid for: Hygiene level XH | Valid for: Hygiene level AD |
| A | 650 to 850 ppm PAA | 1250 to 1750 ppm PAA |
- Repeat Item Reference.
- Increase or decrease the dosing factor.Note: An increase of the dosing factor will decrease the concentration.
- Repeat Item Reference.
TTCU - Set Cleaning Solution Conductivity Depending on Chemical Type
| Equipment Status | Power must be turn OFF.
|
| Special Equipment | Brush Soft cloth Open vessel (Ø 150 mm) |
| Consumables | Acid detergent (TTCU) Alkali detergent (TTCU) Alkali solution (Manual Cleaning) Water |
Note: Conductivity settings must be done each time a new conductivity meter is installed, and each time new chemical products are used for hygiene chamber cleaning.Laboratory Preparations
Hazardous substance.Use protective safety equipment: safety glasses, protective gloves, and an apron when performing this procedure.The procedure below involves a substance that is hazardous to your health.
In the laboratory prepare enough quantities of alkali and acid solutions listed in the table below, using the same drinking water supplied to the TTCU.| Chemical Type | Concentration |
| Alkali | 0.3% |
| Acid | 0.3% |
Concentration Checks
- Make sure that the Conductivity meter is calibrated, see Procedure Chemical Pumps - Calibrate Disinfectant Dosage Pump.
Hazardous substances.Wear safety glasses and protective gloves when removing the conductivity sensor from the tank.Contact with chemicals could be hazardous to your health.
Remove and clean the Sensor according to Procedure Tank Unit - Clean Conductivity Meter Sensor.- Use a clean soft cloth to wipe off the sensor.

- Conductivity meter
- Sensor
- Immerse the conductivity sensor in the alkali solution.
- Make sure the sensor is submerged completely in the solution.
- Make sure the sensor is placed in the middle of the container, minimum 15 mm from the edge.
- Read the conductivity for the first solution and record it.
- Rinse the sensor thoroughly with plenty of water.
- Use a clean soft cloth to wipe off the sensor.
- Repeat Item Reference to Reference for the acid solution.
Set Machine Configuration
- Set the configuration according to Procedure Machine Settings in the PLC, sub procedure Machine Settings in the PLC.
- Check the alkali solution and acid solution according to Procedure Tank Unit - Check Solution Concentration.
The solution concentrations must be according to the table above, see page Reference. If necessary, adjust the conductivity, see below.- Repeat Item Reference.
- Increase or decrease the conductivity value.Note: An increase of the conductivity value will increase the concentration.
- Repeat Item Reference.
Functional Description

- Pump
- Valve
- Strainer
- Pressure gauge
- Flow meter
Pressure Side - Check Pressure Drop Over Strainer
| Equipment Status | Program Step |
- During the cleaning (or disinfection) program when the Pump pumps cleaning solution (or disinfectant solution) check the pressure drop over the Strainer.

- Pump
- Strainer
- Pressure gauge
- Pressure gauge
Pressure Side - Check Centrifugal Pump Impeller
| Equipment Status | Program Step |
Hazardous voltage.The main power supply disconnecter for the TTCU must be switched off and secured with a lock before any maintenance.Will shock, burn or cause death.
Hot parts.Before service, make sure that the pipes are cool before performing this procedure.Pipes and components in the Tetra Top Cleaning Unit can cause burn damages.
- Remove the Cap nut and the Washer to remove the Pump casing.
- Measure the clearance between the Impeller and the Back plate.
- The clearance must be 0.5 mm, if necessary adjust according to Procedure Pressure Side - Set Centrifugal Pump Shaft.

- Cap nut
- Washer
- Back plate
- Impeller
- Pump casing
Pressure Side - Set Flow Meter
| Equipment Status | Program Step |
Hot parts.Let the flow meter cool down before you do any work on it.The flow meter is hot when it has been in use.
- After a successful function check, switch on the measuring device.Note: After a successful startup, the local display automatically switches from the startup display to the operational display.
- Navigate to the
Setup menu.Note: The Setup menu contains all the parameters needed for standard operation. - To enter the
Setup menu, press E. - To go back to the previous menu options, press Esc.
- To jump to the language settings, press E.Press E to change the language.Note: The default language is English.
- To exit the language settings, press Esc (the - and the + buttons at the same time).
- Press E to enter the
Main menu. - Go down to the
Setup menu and press Enter. - Go down to the
System units menu and press Enter. - Go to the
Volume flow unit menu and press Enter.
- Select m3/h and press Enter to confirm.
- To go back to the previous menu options, press Esc.
- Go down to the
Curr.output 1 menu and press Enter. - Select the
Assign curr. 1 menu option and press Enter.
- Go down to the
20 mA menu option and press Enter. - Select
2 and press Enter. - Select
5 and press Enter. - Select the check symbol
and press Enter.Note: The 20 mA value must correspond to 25 m - Finish the setup by pressing Esc three times.
Disable Totalizer (Optional)
- Press E, then go to the
Setup menu by pressing E again. - Go to the
Advanced setup menu and press E.
- Go to the
Totalizer 1 menu and press E. - Press E again and set the value to
Off. - Finish the setup by pressing Esc four times.
- To set Totalizer 2, repeat items Reference to Reference.
Setting the CIP Flow Meter (Older Variant)
Hot parts.Let the flow meter cool down before you do any work on it.The flow meter is hot when it has been in use.
Note: Press the Minus button and the Plus button simultaneously to abort the current selection without saving. Press and hold the same buttons for three seconds to abort the setting procedure.- Loosen the four Screw fully and remove the Cover. The Screw can not be removed from the Cover.
- Press the E button to enter the
Group select mode.Note: When you press a button you need to hold it for about one second. - Press the Plus button one time to step to
System units. 
- Minus button
- Plus button
- Screw
- Cover
- E button
System Units- Press the E button to enter the
System units menu. - Press the Plus button one time to enter the
Unit volume flow menu. The flow meter will ask you to enter an access code. - Enter the access code 0050 using the following method:
- Press the E button to unlock the programming menu when all the four digits are entered. The display will show:
Programming Enabled. - Use the Plus button and the Minus button to step the blinking volume unit to m.
- Press the E button to confirm the volume unit and to step to the time unit.
- Use the Plus button and the Minus button to step the blinking time unit to h.
- Press the E button to confirm the time unit.
- Press the E button three times to step back to the
Group select mode.
User Interface- Press the Plus button three times to step to the
User interface menu. - Press the E button to enter the
User interface menu. - Press the E button one time to enter the
Assign Line 2 menu. - Press the Plus button six times to change to
Assign Line 2 to Off. - Press the E button. The flow meter will ask if you are sure that you want to change the setting.
- Press the Plus button one time to change the
No to Yes. - Press the E button to confirm that you want to change the setting.
- Press the E button one time to step back to the
Group select mode.
Totalizer 1- Press the Plus button one time to step to the
Totalizer 1 menu. - Press the E button to enter the
Totalizer 1 menu. - Press the Plus button one time to enter the
Assign totalizer menu. - Press the Plus button one time to change
Volume flow to Off. - Press the E button. The flow meter will ask if you are sure that you want to change the setting.
- Press the Plus button one time to change the
No to Yes. - Press the E button to confirm that you want to change the setting.
- Press the E button one time to step back to the
Group select mode.
Totalizer 2- Press the Plus button one time to step to the
Totalizer 2 menu. - Press the E button to enter the
Totalizer 2 menu. - Do item Reference to Reference again above, see Reference.
Current Output- Press the Plus button one time to step to the
Current output menu. - Press the E button to enter the
Current output menu. - Press the E button two times to step to the
Value 20 mA menu. - Press the E button one time and enter the value +25 using the following method:
- Use the Plus button and the Minus button to step up or down the digits.
- Press the E button to confirm a digit and to step to the next one.
- Press the E button enter the value when all the digits are entered.Note: You can only enter five digits even though there are six slots for them. When the first five digits are entered the last sixth digit will be deleted.
- Press the E button five times to step back to the
Group select mode. - Press and hold the Minus button and the Plus button simultaneously for three seconds to exit the
Group select mode. - Install the Cover with the Screw.
Pressure Side - Set Centrifugal Pump Shaft
| Equipment Status | Program Step |
Hazardous voltage.The main power supply disconnecter for the TTCU must be switched off and secured with a lock before any maintenance.Will shock, burn or cause death.
Hot parts.Before service, make sure that the pipes are cool before performing this procedure.Pipes and components in the Tetra Top Cleaning Unit can cause burn damages.
- The following parts needs to be removed in order to set the shaft.
- Pump casing
- Safety guard
- Impeller
- Back plate
- For instructions on how to remove these parts see Procedure Pressure Side - Overhaul Centrifugal Pump (disassemble).
- Loosen the Screw and adjust.
- Tighten the Screw evenly to 15 Nm. Counter hold with a Screwdriver.
- Fit the back plate and the impeller according to Procedure Pressure Side - Overhaul Centrifugal Pump (assemble).
- Check the impeller according to Procedure Pressure Side - Check Centrifugal Pump Impeller.
- If further adjustments are needed, adjust according to item Reference to Reference.
- Fit the remaining parts according to Procedure Pressure Side - Overhaul Centrifugal Pump (assemble).

- Screwdriver
- Screw
Pressure Side - Clean the Filter Element in the Strainer
| Equipment Status | Program Step |
| Consumables | Alkali solution (Manual Cleaning) |
Remaining hazardous media. The system could contain hazardous media under pressure. Before service, make sure that the valves and the pipes are drained and pressureless. Use protective safety equipment: safety glasses, protective gloves, and apron.
Hot parts. Pipes and components in the Tetra Top Cleaning Unit can cause burn damages. Before service, make sure that the pipes are cool before performing this procedure.
- Loosen the Wing nut and carefully open the Clamp and let the media flow out slowly.

- Wing nut
- Clamp
- Remove the Clamp.
- Remove the Filter element by grasping it by the Handle and pulling it straight out from the Casing.
- Clean the Filter element carefully with cleaning solution and a brush. Rinse the Filter element thoroughly with water.
- Assemble the strainer in reverse order.Note: Make sure that the Connection piece is installed with the smaller inner diameter towards the strainer.

- Filter element
- Handle
- Casing
- Connection piece
Pressure Side - Change Flow Meter Seals
| Equipment Status | Power must be turn OFF.
|
Hazardous substances.The pipeline that the flow meter is connected to may be full of hazardous substances. Make sure that the pipeline is drained before you do any work on the flow meter.
Hot parts.Let the flow meter cool down before you do any work on it.The flow meter is hot when it has been in use.
- Remove the Clamp.
- Remove the Screw.
- Change the Seal. There is one seal on each side of the flow meter.
- Tighten the Screw until the Pipe connection touches the flow meter.Note: The metal against metal connections between the pipes and the flow meter ensures a defined compression of the Seal.

- Clamp
- Screw
- Seal
- Pipe connection
Pressure Side - Change Flow Meter Fuse
| Equipment Status | Power must be turn OFF.
|
Hazardous voltage.The main power supply disconnecter for the TTCU must be switched off and secured with a lock before any maintenance.Will shock, burn or cause death.
Hot parts.Let the flow meter cool down before you do any work on it.The flow meter is hot when it has been in use.
- Loosen the four Screw fully and remove the Cover . The Screw can not be removed from the Cover.

- Screw
- Cover
- Press in the Latch at the side of the Local display and remove it from the electronics compartment Cover.
- Press in the Latch to disconnect the Ribbon cable.
- Remove the Screw and remove the electronics compartment Cover.
- Remove the Power supply board, insert a suitable tool into the Hole and pull the board clear of its holder.
- Remove the Cap and replace the Device fuse.
- Assemble the board, local display, and covers in the reverse order.

- Latch
- Local display
- Cover
- Latch
- Ribbon cable
- Screw
- Power supply board
- Hole
- Cap
- Device fuse
Pressure Side - Overhaul Divert Valve
| Equipment Status | Program Step Program Step |
| Consumables | Silicone grease: TP No. 344477-0000 |
- Disconnect the Proximity switch and the Air connection from the Valve.
- Disconnect the Valve at the Connection.
- Open the Clamp and remove the Valve from the machine.

- Proximity switch
- Air connection
- Valve
- Connection
- Clamp
- Remove the lower Clamp and the lower Valve body.
Risk of crushing.Be careful when working on the valve so that you will not crush your fingers if the air pressure in the valve releases.The valve contains a spring that will close the valve if it is not being held open by compressed air.
Supply compressed air through the Air connection until the Valve plug releases from the Seat. Do not release the compressed air until told to do so.- Remove the Valve plug and the Seat.
- Release the compressed air.

- Air connection
- Clamp
- Valve body
- Valve plug
- Seat
- Remove the upper Clamp and the upper Valve body.
Risk of damage to the equipment.Be careful when removing the bushing.The bushing will be reused and it can be damaged when it is removed.
Remove the O-ring, the Lip seal, and the Bushing from the Bonnet. Use a bushing tool and a rubber mallet to remove the Bushing.- Install a new O-ring and a new Lip seal.
- Install the Bushing.
- Carefully remove the Plug seal from the Valve plug.
- Carefully install the new Plug seal in the grooves by applying pressure on opposite points on the Plug seal.
- Make sure that any air trapped behind the Plug seal is released.

- Valve plug
- Clamp
- Valve body
- Bushing
- O-ring
- Lip seal
- Bonnet
- Plug seal
- Loosen and remove the two Bushing.
Risk of damage to the equipment.Do not overtighten the bushings.If you overtighten the bushings you will damage the O-rings.
Replace the O-ring, the O-ring, and the Bushing. Lubricate the O-rings before replacing them.- Replace the O-ring on the Seat with new ones.
- Install the upper Valve body with the upper Clamp.
- Supply compressed air through the Air connection until the Valve plug can be fully screwed on and then screw it on.
- Release the compressed air.
- Install the lower Valve body with the lower Clamp.

- Air connection
- Clamp
- Valve body
- Valve plug
- Seat
- Clamp
- Valve body
- Bushing
- O-ring
- O-ring
- O-ring
- Install the Valve with the Clamp.
- Connect the Valve at the Connection.
- Connect the Proximity switch and the Air connection to the Valve.

- Proximity switch
- Air connection
- Valve
- Connection
- Clamp
Pressure Side - Overhaul Strainer
| Equipment Status | Program Step |
| Consumables | Alkali solution (Manual Cleaning) |
Remaining hazardous media. The system could contain hazardous media under pressure. Before service, make sure that the valves and the pipes are drained and pressureless. Use protective safety equipment: safety glasses, protective gloves, and apron.
Hot parts. Pipes and components in the Tetra Top Cleaning Unit can cause burn damages. Before service, make sure that the pipes are cool before performing this procedure.
- Loosen the Wing nut and carefully open the Clamp and let the media flow out slowly.

- Wing nut
- Clamp
- Gasket
- Remove the Clamp.
- Remove the Gasket and the O-ring.

- Clamp
- Gasket
- O-ring
- Remove the Filter element by grasping it by the Handle and pulling it straight out from the Casing.
- Loosen the Nut and remove the Flat packing and Handle from the Filter element.
- Remove the O-ring, the Gasket, and the Gasket.
- Clean the parts carefully.
- Clean the Filter element carefully with cleaning solution and a brush. Rinse the Filter element thoroughly with water.
- Change to new spare parts.
- Assemble the strainer in reverse order.Note: Make sure that the Connection piece is installed with the smaller inner diameter towards the strainer.

- Filter element
- Handle
- Casing
- Nut
- Flat packing
- O-ring
- Gasket
- Gasket
- Connection piece
Pressure Side - Overhaul Centrifugal Pump
| Equipment Status | Program Step |
| Special Equipment | Tool: TP No. 6-9612137101 |
| Consumables | Silicone grease: TP No. 344477-0000 Contact cleaner: TP No. 90600-6077 |
Hazardous voltage.The main power supply disconnecter for the TTCU must be switched off and secured with a lock before any maintenance.Will shock, burn or cause death.
Burn hazard.The pump is hot, allow it to cool down before maintenance.
Disassemble
- Remove the Cap nut, the Washer, and the Pump casing.
- Remove the Screw and the Safety guard.
- Remove the Impeller screw.
- Remove the Impeller. If necessary, loosen the impeller by knocking gently on the impeller vanes.
- Remove the O-ring from the impeller.

The
Safety guard can vary on machines with different serial numbers
- Cap nut
- Washer
- Pump casing
- Screw
- Safety guard
- Impeller screw
- Impeller
- O-ring
- Pull off the O-ring from the Back plate.
- Remove the Nut and the Washer to remove the Back plate.
- Remove the Stationary seal ring by using the Tool. The stationary seal ring is left-hand threaded.
- Remove the O-ring from the Back plate.

- O-ring
- Back plate
- Nut
- Washer
- Stationary seal ring
- Tool
- O-ring
- Remove the Drive ring from the Stub shaft, or remove the complete shaft seal from the Stub shaft.
- Remove the Spring, the O-ring, and the Rotating seal ring from the Drive ring.

- Stub shaft
- Drive ring
- Spring
- O-ring
- Rotating seal ring
Parts to be changed
The following parts are included in the spare part kit and must be changed during this overhaul procedure when assembling the pump.
- O-ring
- O-ring
- Stationary seal ring
- O-ring
- Spring
- O-ring
- Rotating seal ring
Assemble
Note: Lubricate O-rings and rubber seals with silicone grease or similar.- Fit the O-ring in the Rotating seal ring. Make sure that the O-ring has maximum clearance from the sealing surface.
- Fit the Spring in the Rotating seal ring.
- Fit the Rotating seal ring on the Drive ring.

A = Maximum
- Drive ring
- Spring
- O-ring
- Rotating seal ring
- Make sure that the driver on the Drive ring enters the notch in the Rotating seal ring.

- Drive ring
- Rotating seal ring
- Fit the complete shaft seal on the Stub shaft so that the Connex pin enters the notch in the Drive ring.

- Stub shaft
- Drive ring
- Connex pin
- Fit the O-ring on the Stationary seal ring and lubricate.
- Use the Tool to fit the left-hand threaded Stationary seal ring into the Back plate. Tighten to maximum 7Nm.Note: When fitting the left-hand threaded Stationary seal ring, only tighten by hand to avoid deformation of the stationary seal ring.

- Back plate
- Stationary seal ring
- Tool
- O-ring
- Clean the sealing surfaces with contact cleaner before fitting the Back plate.
- Carefully guide the Back plate onto the Adaptor.
- Assemble with the Washer and the Nut.

- Back plate
- Nut
- Washer
- Adaptor
- Lubricate the O-ring and slide it onto the Back plate.

- O-ring
- Back plate
- Lubricate the O-ring and fit it in the Impeller.
- Lubricate the impeller hub with silicone grease or similar.
- Fit the Impeller onto the Stub shaft.
- Fit the Impeller screw and tighten to 20Nm.

- Impeller screw
- Impeller
- O-ring
- Stub shaft
- Fit the Safety guard and tighten the Screw.

The
Safety guard can vary on machines with different serial numbers
- Screw
- Safety guard
- Fit the Cap nut and the Washer to the Pump casing.
- Adjust the Pump casing to the right position and tighten the Cap nut.

- Cap nut
- Washer
- Pump casing
Pressure Side - Check Filter and Pipe
| Equipment Status | Program Step |
- Remove the Clamp and the Clamp.
- Remove the Pipe.
- Check the Pipe and the Filter for sprues. Clean if necessary.
- Change the bottom Gasket if needed.
- Assemble in reverse order.

- Clamp
- Pipe
- Filter
- Gasket
Functional Description
The Water supply (see page Water Supply) and the Steam inlet is mounted on the tank lid. The tank have an Alkali inlet and an Acid inlet. The Disinfectant inlet is mounted on the water supply.The tank is provided with a Temperature sensor and a Conductivity meter. The conductivity meter measures the alkali solutions and acid solutions. Both the temperature and the conductivity is monitored by the logger (see page Logger SM1000). 
A = The tank as seen with the left door openB = The tank as seen with the right door open
- Water supply
- Steam inlet
- Alkali inlet
- Acid inlet
- Disinfectant inlet
- Temperature sensor
- Conductivity meter
The tank level is controlled by the signals from the Level switch.The tank is also provided with a Valve controlling media to a test outlet. The test outlet is used for taking samples of the liquid in the tank. The concentration test must be done when the unit is installed as part of the commissioning and as a quality assurance follow up. The concentration check (titration) is under laboratory responsibility, but taking the sample can be done by an operator.
A = The tank as seen with the left door openB = The tank as seen with the right door open
- Level switch
- Valve
Tank Unit - Check Solution Concentration
| Equipment Status | Program Step |
| Special Equipment | Graduated glass (>200ml) |
This procedure can be done to take samples of alkali solution, acid solution, or disinfection solution. Tank drain, disinfection, Tank drain, alkali, and Tank drain, acid under the Information sign, disinfection, the Information sign, alkali , and the Information sign, acid flashes when the sample can be taken.
- Tank drain, disinfection
- Tank drain, alkali
- Tank drain, acid
- Information sign, disinfection
- Information sign, alkali
- Information sign, acid
- Start cleaning or disinfection of the hygiene chamber from the TPOP, see OM.
- Open the Door.
Hazardous substances.Always wear personal protective equipment. Read the manufacturer’s instructions and carefully follow the warning texts on the containers. Also see the section
Hazardous Substances in the Safety Precautions chapter.Contact with chemicals could be hazardous to your health.
Use a clean Cup and place it under the Outlet.- When the Tank drain on the TTCU starts to flash, press Tank drain. Keep the Tank drain depressed until the cup contains 200 ml.
- Dispose the liquid in the cup according to local regulations.
- Use a clean Cup and place it under the Outlet.
- Take a new sample by pressing the Tank drain again. Keep theTank drain depressed until the cup contains 200 ml.
- Send the samples to the laboratory for titration.

- Door
- Cup
- Outlet
- Tank drain
Tank Unit - Check Over Filling Pipe Screen Gasket
| Equipment Status | Program Step |
| Consumables | Alkali solution (Manual Cleaning) |
- Remove the Clamp and pull the Over filling pipe downwards.
- Check the condition of the Screen gasket.If necessary, clean the Screen gasket using cleaning solution and a brush, or change the screen gasket if it is damaged.
- Assemble the Over filling pipe in the reverse order.

- Clamp
- Over filling pipe
- Screen gasket
Tank Unit - Check Conductivity Meter Cell Calibration
| Equipment Status | Program Step Program Step |
| Special Equipment | Calibration Tool 3069205-0000 |
Hazardous substances.Wear safety glasses and protective gloves when removing the conductivity sensor from the tank.Contact with chemicals could be hazardous to your health.
- Remove the four Screw and remove the Housing cover.
- Remove the conductivity meter from the tank and clean the sensor according to procedure Tank Unit - Clean Conductivity Meter Sensor.
- Make sure that the sensor is dry before performing the check.
- Press thePlus (+) button until UncompVal is displayed.
- Check that the reading is 0 mS/cm.

- Screw
- Housing cover
- Cal button
- Plus (+) button
- Minus (-) button
- E button
- Insert the Cable of the calibration tool through the Sensor of the conductivity meter and connect it to the calibration tool.
- Check that the reading is 59±2 mS/cm.
- If the reading is not 59±2 mS/cm then perform a cell calibration according to Procedure Tank Unit - Calibrate Conductivity Meter Cell on page Tank Unit - Calibrate Conductivity Meter Cell.
- Press the
Plus (+) button to exit UncompVal. - Remove the wire and the calibration tool.

- Cable
- Sensor
- Assemble the housing cover on the conductivity meter.
- Assemble the Conductivity meter and tighten the Clamp. Make sure that the Sensor is correctly positioned, the orientation arrow on the sensor must point downwards.

- Sensor
- Conductivity meter
- Clamp
Tank Unit - Set Conductivity Meter (Calibrate)
| Equipment Status | Program Step Program Step |
- Remove the four Screw and remove the Housing cover.
- Clean the sensor according to Procedure Tank Unit - Clean Conductivity Meter Sensor on page Tank Unit - Clean Conductivity Meter Sensor.
- Press the Cal button.
- Use the Plus (+) button or the Minus (-) button to enter the calibration access code and press the E button.
| Calibration access code (calibration mode) | 22 |
| Calibration access code(view mode) | 0 |

- Screw
- Housing cover
- Cal button
- Plus (+) button
- Minus (-) button
- E button
Calibration
Note: Use the Plus (+) button or the minus (-) button (5) to select parameters of different function groups.Note: Press the Plus (+) button and the minus (-) button (5) simultaneously to quit.- Press the E button to enter the Calibrate menu.
- Press the E button to enter the AirS Calibrate menu.
- Press the E button to start AirSet calibration.
- Press the E button to confirm AirSetVal.
- Press the E button to confirm the calibration status o.k.
- Press the E button to store the calibration results.
- Press the E button to return to the
Calibration access code menu.
Setup 1
- Press theE button to select the
Setup 1 function group. - Press theE button to enter the
Setup 1 menu. - Select operating mode
Cond and press the E button to confirm the setting. - Select unit displayed ppm and press the E button to confirm the setting.
- Select format XX.xx and press the E button to confirm the setting.
- Select unit mS/cm and press the E button to confirm the setting.
- Select cell constant 5.900 and press the E button to confirm the setting.
- Select installation factor 1 and press the E button to confirm the setting.
- Select damping 1 (no damping) and press the E button to confirm the setting. The display returns to the
Setup 1 menu.
Setup 2
- Press theMinus (-) button to select the
Setup 2 function group. - Press theE button to enter the
Setup 2 menu. - Select temperature sensor Pt 100d and press the E button to confirm the setting.
- Select temperature compensation type lin and press theE button to confirm the setting.
- Select alfa value 2.10%/K and press the E button to confirm the setting.
- Press theE button to confirm the temperature reading.
- Press theE button to confirm the temperature setting. The display returns to the
Setup 2 menu.
Current Output
- Press the Minus (-) button to select the
Output function group. - Press the E button to enter the
Output menu. - Select Out 1 and press the E button to confirm the setting.
- Select lin and press the E button to confirm the setting.
- Select current range 4-20 mA and press the E button to confirm the setting.
- Select 0 (µS/cm) and press the E button to confirm the setting.
- Select 100 (mS/cm) and press the E button to confirm the setting. The display returns to the
Output menu. - Press the E button to enter the
Output menu. - Press the Plus (+) button to select Out 2 and press the E button to confirm the setting.
- Select lin and press the E button to confirm the setting.
- Select current range 4-20 mA and press theE button to confirm the setting.
- Select 0 (°C) and press the E button to confirm the setting.
- Select 100 (°C) and press the E button to confirm the setting. The display returns to the
Output menu.
Measuring mode
- Press the Plus (+) button and the Minus (-) button simultaneously to return to measuring mode.
- Assemble the conductivity meter in the reverse order.
Tank Unit - Clean Conductivity Meter Sensor
| Equipment Status | Program Step |
| Consumables | Alkali solution (Manual Cleaning) |
Hazardous substances.Wear safety glasses and protective gloves when removing the conductivity sensor from the tank.Contact with chemicals could be hazardous to your health.
- Remove the Conductivity meter from the Tank by removing the Clamp and the Gasket.
- Carefully remove any coating from the Sensor using cleaning solution and a brush.
- Rinse the Sensor thoroughly with plenty of water.
- Assemble the Conductivity meter and tighten the Clamp. Make sure that the Sensor is correctly positioned, the orientation arrow on the sensor must point downwards.

- Conductivity meter
- Tank
- Clamp
- Gasket
- Sensor
Tank Unit - Change Sampling Valve Diaphragm
| Equipment Status | Program Step Program Step |
Hazardous substances.Wear safety glasses and protective gloves when maintaining the sampling valve.Contact with chemicals could be hazardous to your health.
- Disconnect the Hose by removing the hose clip.
- Remove the Pneumatic hose.
- Remove the Clamp and the Gasket, and place the Valve on a clean suitable working area.

- Hose
- Pneumatic hose
- Clamp
- Gasket
- Valve
- Remove the Screw and washer and separate the Valve seat and the Actuator.
- Change the Diaphragm.
- Assemble the sampling valve in the reverse order. Tighten the screws to an approximately torque of 1.5 Nm.

- Screw and washer
- Valve seat
- Actuator
- Diaphragm
Tank Unit - Overhaul Angle Seat Valve
| Equipment Status | Program Step Program Step Program Step |
| Consumables | Alkali solution (Manual Cleaning) |
- Turn off the main steam supply and the main water supply.
- Activate the angle seat valve Actuator to the opened position.

- Actuator
- Pneumatic valve ramp
- Knob
- Angle seat valve
- Loosen the Union nut.
- Deactivate the Actuator. The valve is in closed position.
- Remove the actuator assembly from the Valve body.
- Remove the Sealing washer.
- Remove the Nut and the Shut-off seal.
- Clean all parts.
- Place a new Sealing washer and a new Shut-off seal in the assembly.
- Replace the Nut.
- Activate the Actuator to the opened position.
- Assemble the actuator assembly and tighten the Union nut.
- Deactivate the Actuator. The valve is in closed position.

- Actuator
- Union nut
- Valve body
- Sealing washer
- Nut
- Shut-off seal
Tank Unit - Calibrate Conductivity Meter Cell
| Equipment Status | Program Step Program Step |
| Special Equipment | Calibration Tool 3069205-0000 |
Hazardous substances.Wear safety glasses and protective gloves when removing the conductivity sensor from the tank.Contact with chemicals could be hazardous to your health.
Note: Before performing the cell calibration, make sure the conductivity meter has been set according to Procedure .- Remove the conductivity meter from the tank and clean the sensor according to Procedure Tank Unit - Clean Conductivity Meter Sensor.
- Make sure that the sensor is dry before performing the calibration.
- Remove the four Screw and remove the Housing cover.
- Press the Cal button.
- Use the Plus (+) button or the Minus (-) button to enter the calibration access code 22 and press the E button.

- Screw
- Housing cover
- Cal button
- Plus (+) button
- Minus (-) button
- E button
Note: Use the Plus (+) button or the Minus (-) button to select parameters of different function groups.Note: Press the Plus (+) button and the Minus (-) button simultaneously to quit.- Insert the Cable of the calibration tool through the Sensor of the conductivity meter and connect it to the calibration tool.
- Press the Cal button.
- Use the Plus (+) button or the Minus (-) button to enter the calibration access code 22 and press the E button.
- Press the E button to enter the
Calibrate menu. - Press the Plus (+) button to select
Cellc Calibrate. - Press the E button to enter
Cellc Calibrate. - Use the Plus (+) button or the Minus (-) button to enter
0 %/K in alpha val. - Press the E button to confirm
alpha val. - Use the Plus (+) button or the Minus (-) button to enter
59 mS/cm in Real. val. - Press the E button to confirm
Real. val. - Press the E button to confirm
Cyclones. - Press the E button to confirm
Status. - Press the E button to
Store. 
- Cable
- Sensor
Final Check
- Press the Plus (+) button until
UncompVal is displayed. - Disconnect the wire from the calibration tool until the conductivity value in the display drops to 0 mS/cm.
- Reconnect the wire to the calibration tool and verify that the conductivity value in the display is 59±2 mS/cm.
- If the reading is not 59±2 mS/cm then perform the cell calibration again.
- Remove the wire and the calibration tool.
- Assemble the housing cover on the conductivity meter.
- Assemble the Conductivity meter and tighten the Clamp. Make sure that the Sensor is correctly positioned, the orientation arrow on the sensor must point downwards.

- Conductivity meter
- Tank
- Clamp
- Gasket
- Sensor
Water Supply - Set Flow Sensor Disinfectant
| Equipment Status | Program Step |
| Special Equipment | Slotted screwdriver 2 mm |
- Make sure that the Disinfection pump is calibrated. See Procedure Chemical Pumps - Calibrate Disinfectant Dosage Pump.
- Start the Disinfection pump by pressing the 100% button and holding it depressed.
- View the backside of the pump, make sure that the pump pumps disinfectant from the Pick-up tube in the container to the Hose connected at the mounting plate.
- Press the 100% button for approximately 5sec.
- Release the 100% button.

- Disinfection pump
- 100% button
- Pick-up tube
- Hose
- Use a small screwdriver to adjust the Flow sensor until the Red LED just begin to light up.
- Start the Disinfection pump by pressing the 100% button and hold it depressed.
- When the Disinfection pump pumps disinfectant, adjust the Flow sensor.
- Use a small screwdriver to adjust the flow sensor until all the Green LED light up.
- Release the 100% button. Make sure that the Red LED is lit as soon as disinfectant flow stops.
- Run the external disinfection program for example an intermediate disinfection, according to the Operation Manual.
- When the Disinfection pump pumps disinfectant, adjust the Flow sensor. Use a small screwdriver to adjust the flow sensor until one or two Green LED light up.Note: When the Disinfection pump pumps disinfectant, the indication (number of LED lit) on the flow sensor must be seen as pulses.
- Make sure that at least the Yellow LED on the flow sensor is lit when the disinfectant pump is pumping.
- Make sure that the Red LED is lit as soon as disinfectant flow stops.

- Disinfection pump
- 100% button
- Flow sensor
- LEDRed
- LEDYellow
- LEDGreen
Water Supply - Change the Flow Sensor Unit
| Equipment Status | Program Step Program Step |
- Disconnect the electrical cable.
- Loosen the Lock screw.
- Remove the old Sensor unit by turning and lifting it away from the Paddle-wheel unit.
- Attach the new Sensor unit.
- Tighten the Lock screw.
- Connect the electrical cable.

- Lock screw
- Sensor unit
- Paddle-wheel unit
Steam Unit
Hot steam.Pipes and components can be extremely hot. Use protective gloves when handling the regulator valve or turning OFF the supply valve. Use caution when working inside the equipment.Hot steam can cause serious burn damaged.
Pressurized steam.To prevent injury, turn off the supply valve, depressurize the equipment and vent all steam safely before working on the equipment.Pressurized steam can be discharged unexpectedly.
Steam Unit - Set Pressure
| Equipment Status | Program Step |
Hot steam.Hot steam can cause serious burn damaged. Pipes and components can be extremely hot. Use protective gloves when handling the regulator valve or turning OFF the supply valve. Use caution when working inside the equipment.
- To set the steam pressure, turn the Adjustment hand wheel on the regulator valve until the Pressure gauge reads approximately 200 kPa (2 bar).

- Adjustment hand wheel
- Pressure gauge
Steam Unit - Clean Strainer
| Equipment Status | Program Step |
Hot steam.Hot steam can cause serious burn damage. Pipes and components can be extremely hot. Use protective gloves when handling the regulator valve or turning OFF the supply valve. Use caution when working inside the equipment.
Pressurized steam.To prevent injury, turn off the supply valve, depressurize the equipment, and vent all steam safely before working on the equipment.Pressurized steam can be discharged unexpectedly.
- Turn off the main steam supply by turning the Ball valve to closed position. Check that the Gauge reads 0 kPa (0 bar).
- Activate the angle seat valve Actuator to the opened position,

- Ball valve
- Gauge
- Actuator
- Pneumatic valve ramp
- Knob
- Angle seat valve
- Remove the Screw and washer.
- Remove the Cover.
- Open the End cap on the Strainer and take out the Mesh. Clean the Mesh by using compressed air.
- Assemble the Strainer.
- Assemble the Cover and tighten the Screw and washer.
- Turn on the steam supply by slowly turning the Ball valve to open position. Check that the Gauge reads approximately 200 kPa (2 bar).

- Ball valve
- Gauge
- Screw and washer
- Cover
- End cap
- Strainer
- Mesh
Functional Description
At the return side the liquid from the TT/3 filling machine is diverted by the Valve back into the tank again or to the drain.
- Valve
Functional Description
The Disinfectant dosage pump is a self-priming diaphragm pump.The detergent (alkali and acid) pumps are pneumatically controlled. Any procedure valid for the Alkali pump is also valid for the Acid pump, and vice versa.
- Disinfectant dosage pump
- Alkali pump
- Acid pump
Chemical Pumps - Check Disinfectant Dosage Pump
| Equipment Status | Program Step |
Hazardous substance.Use protective safety equipment: safety glasses, protective gloves, and an apron when performing this procedure.The procedure below involves a substance that is hazardous to your health.
- Check that there is no leakage from the Drain hole in the Dosing head.

Top left: The pump as seen from the side
- Drain hole
- Dosing head
- Disinfectant pump
Chemical Pumps - Check Detergent Dosage Pump
| Equipment Status | Program Step |
Hazardous substance.Use protective safety equipment: safety glasses, protective gloves, and an apron when performing this procedure.The procedure below involves a substance that is hazardous to your health.
- Make sure that the Pneumatic connection and the Hose are not damaged. If necessary, change the pneumatic connection and the hose.
- Make sure tightened Pneumatic connection is tightened.
- Check that there are no leakage from
- Make sure that the Chemical connection is tightened.

The illustrations shows the acid pump
- Pneumatic connection
- Hose
- Top retrainer
- Bottom retrainer
- T-connection
- Pump
- Chemical connection
Chemical Pumps - Check Pick-up Tube and Hose
| Equipment Status | Program Step |
Hazardous substance.Use protective safety equipment: safety glasses, protective gloves, and an apron when performing this procedure.The procedure below involves a substance that is hazardous to your health.
- Check the condition of the Pick-up tube, the Hose, and the Hose.Make sure that:
- there are no leakage
- the hoses are transparent and that it has no colour changes
- the hoses are flexible and not brittle
If necessary, change the pick-up tubes and hoses according to Procedure Chemical Pumps - Change Pick-up Tube and Hose on page Chemical Pumps - Change Pick-up Tube and Hose.
- Pick-up tube
- Hose
- Hose
Chemical Pumps - Calibrate Disinfectant Dosage Pump
| Equipment Status | Program Step |
| Special Equipment | Graduated glass (>1000 ml) |
| Consumables | Disinfectant (Peracetic acid solution 1500 ppm PAA) |
Hazardous substance.Use protective safety equipment: safety glasses, protective gloves, and an apron when performing this procedure.The procedure below involves a substance that is hazardous to your health.
- Press
Hygiene chamber cleaning/disinfection on the TPOP and select Disinfection, see OM. - Make sure that the Pick-up tube is immersed in the oxonia.
- Start the Disinfectant pump by pressing the 100% button and hold it depressed for approximately 5 seconds.
- Look at the backside of the pump, make sure that the pump pumps disinfectant from the Pick-up tube in the container to the Hose connected at the mounting plate.
- Release the 100% button.

The pump as seen from the frontThe pump as seen from the side
- Disinfectant pump
- 100% button
- Pick-up tube
- Hose
- Stop the disinfectant dosage pump by pressing the Play/STOP button. The Display turns light blue.
- Fill a Graduated glass with dosing liquid Q1, approximately 1000 ml.
- Read the quantity of the dosing liquid Q1 and make a note of it.
- Put the Pick-up tube in the Graduated glass.
- Turn the Click wheel to highlight the Cog symbol of the set up menu.
- Press the Click wheel to enter the set up menu.
- Turn the Click wheel to the Calibration menu and press the Click wheel.
- Turn the Click wheel to the Start option.
- Press the Click wheel to start.

The pump as seen from the frontThe pump as seen from the side
- Pick-up tube
- Play/STOP button
- Display
- Graduated glass
- Click wheel
- Cog symbol
- When the pump has performed the 200 dosing strokes the preset value appears in the Display. Remove the Pick-up tube from the Graduated glass and read the remaining dosing liquid Q2.
- Calculate the difference according to the formula
- Q = Q1 - Q2
- Set the display value to Q, by turning the Click wheel to calibrate volume and press the Click wheel.
- Set the display value by turning the Click wheel.
- Press the Click wheel to confirm.
- Turn the Click wheel to the House symbol and press the Click wheel.
- Start the disinfectant dosage pump by pressing the Play/STOP button. The Display turns green.

The pump as seen from the frontThe pump as seen from the side
- Pick-up tube
- Play/STOP button
- Display
- Graduated glass
- House symbol
Valve and Diaphragm - Replace
| Equipment Status | Air must be turn OFF.
|
| Special Equipment | Spare part kit: 90610-1432 |
Follow the instructions to replace the valve and diagram.
- Safety diaphragm
- Flange
- O-ring
- Diaphragm
- Valve on discharge side
- Valve on suction side
- Dosing head
- Screws with discs
- Cover
- Deaeration valve
- Drain opening
Diaphragm and Valve - Remove
- Make system pressureless.
- Empty dosing head before maintenance and flush it if necessary.
- Set pump to "Stop" operating state using the
[Start/stop] key. - Press the
[Start/stop] and [100%] buttons at the same time to put the diaphragm into "out" position. The – symbol must be displayed. - Ensure that the returning liquid is safely collected.
- Dismantle suction, pressure, and deaeration hose.
- Dismantle the Valve on discharge side and the Valve on suction side.
- Remove the Cover.
- Loosen and remove the Screws with discs on the Dosing head.
- Remove the Dosing head.
- Unscrew the Diaphragm turning it to the left, and remove it with the Flange.
- Make sure the drain opening (11) is not blocked or soiled. Clean if necessary.
- Check the safety diaphragm Safety diaphragm for wear and damage. Replace if necessary.
Diaphragm and Valve - Install
- Attach the Flange correctly and screw on new Diaphragm turning in to the right.Note: Make sure that the O-ring is seated correctly.
- Press the
[Start/stop] and [100%] buttons at the same time to put the diaphragm into "in" position. The – symbol must be displayed. - Attach the Dosing head.
- Install the Screws with discs and cross-tighten with a torque wrench.Note: Use a torque of 4 Nm.
- Attach the Cover.
- Install the Valve on discharge side and the Valve on suction side.Note: Do not interchange valves and pay attention to direction of arrow.
- Connect suction, pressure, and deaeration hoses.
- To leave the service mode, press the
[Start/stop] button. - Deaerate dosing pump.
- Perform commissioning.
Chemical Pumps - Clean Disinfectant Dosage Pump
| Equipment Status | Program Step |
| Special Equipment | 2 x 10 litre bucket |
| Consumables | Water |
Hazardous substance.Use protective safety equipment: safety glasses, protective gloves, and an apron.The pump contain a substance that is hazardous to your health. Remove the hazardous substance before continuing with the work.
- Fill a 10 litre Bucket with water.
- Place the Pick-up tube in the Bucket.
- Remove the Hose from the mounting plate in the frame work and place the hoses in an empty 10 litre Bucket.

- Bucket
- Pick-up tube
- Hose
- Bucket
- Press
Hygiene chamber cleaning/disinfection on the TPOP and select Disinfection, see OM. - Start the Disinfectant pump by pressing the 100% button and hold it depressed.
- Keep the 100% button depressed for approximately 5 minutes, to flush out the hazardous liquid from the pump.
- Release the 100% button.
- Put the Hose back on the mounting plate.
- Dispose the contents of the Bucket according to local regulations.

- Hose
- Bucket
- Disinfectant pump
- 100% button
Chemical Pumps - Clean Detergent Dosage Pump
| Equipment Status | Program Step |
| Special Equipment | 2 x 10 lite bucket |
| Consumables | Water |
Hazardous substance.Use protective safety equipment: safety glasses, protective gloves, and an apron.The pump contain a substance that is hazardous to your health. Remove the hazardous substance before continuing with the work.
- Fill a 10 litre Bucket with water.
- Place the Pick-up tube in the Bucket.
- Remove the Hose from the mounting plate in the frame work and place the hoses in an empty 10 litre Bucket.
- Press
Hygiene chamber cleaning/disinfection on the TPOP and select Disinfection, see OM. 
- Bucket
- Pick-up tube
- Hose
- Bucket
- Activate the Pump with compressed air to flush out the hazardous liquid from the pump. See Procedure Pneumatic Unit - Set Pressure Regulator on page Pneumatic Unit - Set Pressure Regulator for guidance.
- Put the Hose back on the mounting plate.
- Dispose the contents of the Bucket according to local regulations.

- Hose
- Bucket
- Pump
Chemical Pumps - Change Detergent Dosage Pump
| Equipment Status | Program Step Program Step |
Hazardous substance.Remove the hazardous substance before continuing with the work.The pump can contain a substance that is hazardous to your health.
- Make sure that the Pump has been emptied from hazardous liquid, see Procedure Chemical Pumps - Clean Detergent Dosage Pump on page Chemical Pumps - Clean Detergent Dosage Pump.
- Disconnect the Pneumatic hose for the Pump. Make sure that all air pressures is allowed to bleed from the Pump.
- Disconnect the Outlet hose for the Pump by removing the hose clip.
- Disconnect the Inlet hose for the Pump by removing the hose clip.

- Pump
- Pneumatic hose
- Outlet hose
- Inlet hose
- Remove the Screw, the Washer, and the Nut. Repeat for all four attachment points of Pump.
- Change the pump.
- Blow out air from the pneumatic hose for 10 to 20 seconds before connecting it to the pump to make sure that the hose is clear from all particles/debris.
- Assemble the Pump in reverse order.

- Pump
- Screw
- Washer
- Nut
Chemical Pumps - Change Pick-up Tube and Hose
| Equipment Status | Program Step |
| Special Equipment | Heating gun |
| Consumables | Adhesive tape |
Hazardous substance.Use protective safety equipment: safety glasses, protective gloves, and an apron when performing this procedure.The procedure below involves a substance that is hazardous to your health.
- Clean the Pick-up tube according to Procedure
- Turn off the TTCU main power supply.
- Disconnect the Pick-up tube electrical cable from the electrical cabinet, see the Electrical Manual.

- Pick-up tube
- Disconnect the Hose from the Pump by removing the hose clip.
- Disconnect the Hose from the Pump by removing the hose clip. Change to a new hose.
- Remove the pick-up tube Cover from the Holder, by removing the Screw.

The illustrations shows the alkali pump
- Hose
- Pump
- Hose
- Cover
- Holder
- Screw
Note: Do not remove the Cover.- Place the Pick-up tube and cover on a clean suitable working area. Gently pull out the Hose just enough to remove the Strainer.
- Fasten the new Hose on the end of the old Hose, using adhesive tape.
- Pull out the old Hose from the Cover.
- Carefully heat the end of the new Hose using a heat gun.
- Fit the Strainer in the Hose .
- Push in the strainer and hose in the pick-up tube, heat the hose if necessary.
- Assemble the Pick-up tube and cover in the revers order.

- Hose
- Cover
- Pick-up tube and cover
- Strainer
- Hose
Functional Description
The pneumatic unit consist of the Valve ramp, the Air supply unit, and the Air regulator unit.The Valve ramp is a valve terminal designated CDVI-DN, Clean Design valve terminal with field bus direct connection for DeviceNet. The CDVI-DN has a Base block with 4 valve locations and an Extension block with 2 valve locations.The compressed air, connected from the site distribution system, enters the Air supply unit Shut-off valve and then runs through a 40 micron filter in the Pressure regulator. If the supply pressure is too low the Pressure switch will be turned on and an alarm will appear on the TPOP. The Pressure regulator regulates the air to the Valve ramp to a preset pressure.The Air regulator unit, regulates the air to the pneumatically controlled pumps, used for dosing alkali and acid to the tank. The Pressure regulator, alkali regulates the air to the alkali pump, and the Pressure regulator, acid regulates the air to the acid pump.The pneumatic unit also include the cleaning solution Test outlet used for taking samples from the tank during cleaning and disinfection of the hygiene chamber of the filling machine.
- Valve ramp
- Air supply unit
- Air regulator unit
- Base block
- Extension block
- Shut-off valve
- Pressure regulator
- Pressure switch
- Pressure regulator
- Pressure regulator, alkali
- Pressure regulator, acid
- Test outlet
Pneumatic Unit - Set Pressure
| Equipment Status | Program Step |
- Set the main air pressure to 630 kPa (6.3 bar) by turning the Hand wheel on the Pressure regulator.

- Hand wheel
- Pressure regulator
Pneumatic Unit - Set Pressure Switch
| Equipment Status | Program Step Program Step |
- Open the door to the electrical cabinet. Locate the I/O module and the channel status indicator (the 0 (zero) LED), related to the pressure switch using the EM.
- Regulate the main air by turning the Hand wheel pressure until the Pressure gauge reads 530 kPa (5.3 bar).
- Slowly turn the Adjustment screw on the Pressure switch until the 0 (zero) LED is not lit.
- Adjust the main air inlet pressure according to the Procedure Pneumatic Unit - Set Pressure on page Pneumatic Unit - Set Pressure.
- Make sure that the 0 (zero) LED is yellow.
- Close the door to the electrical cabinet.
- If the alarm
Low air pressure is visible on the TPOP, reset it. - I/O module
- Hand wheel
- Pressure gauge
- Adjustment screw
- Pressure switch
Pneumatic Unit - Set Pressure Regulator
| Equipment Status | Program Step |
| Special Equipment | Pneumatic scheme 2937245-0000 |
This setting procedure is valid for both the pressure regulator (V80R0210) that regulates the air to the alkali pump, and the pressure regulator (V80R0220) that regulates the air to the acid pump.- Locate the Pneumatic valve and the small Knob, related to the Pressure regulator using the pneumatic scheme.
- Depress the small Knob and keep it depressed.
- Read the pressure on the Pressure gauge. If necessary, set the air pressure to 250 kPa (2.5 bar) by turning the Hand wheel on the Pressure regulator.
- Release the small Knob.

- Pneumatic valve
- Knob
- Pressure regulator
- Pressure gauge
- Hand wheel
Pneumatic Unit - Set Valve Ramp DIL-switches
| Equipment Status | Program Step Program Step |
Preparations
- Turn off the power supply.
- Turn off the compressed air.
- Remove the Screw and turn the valve ramp to get access to the back.
- Remove the Pneumatic hose and the Pneumatic hose.
- Remove the four Screw.

- Screw
- Pneumatic hose
- Pneumatic hose
- Screw
Risk of damage to the equipment.Do not touch the electrical contacts of the components.The CDVI-DN contains electrostatically sensitive components.
To avoid tilting and squeezing the Separator seal, loosen the two Fastening screw on the End plate by approximately 1 turn. Remove the two Fastening screw completely.- Pull off the End plate.

- Separator seal
- Fastening screw
- End plate
Set DIL Switches
- Set the following parameters on the DIL switches: Extensions to the CP system, Reserved, Baud rate, and The station number (slave address). See the table and the illustration below.
| Pos | Parameter | Setting (meaning) in this application |
| 1 | Extensions to the CP system | CDVI-DN with 4 locations + extension blocks without CP extension |
| 2 | Reserved | Not used |
| 3 | Baud rate | 500 kbaud |
| 4 | The station number (slave address) | Station number 15 |

- Extensions to the CP system
- Reserved
- Baud rate
- The station number (slave address)
Assembly
- Make sure that the Separator seal sits correctly on the guide sleeves of the Base block.
- Assemble the End plate and tighten the two Fastening screw crosswise.Note: Make sure that the separator seal is not squashed on one side as a result of unequal tightening of the fastening screws. The requirements of the IP protection class cannot be fulfilled if a seal is squashed.

- Separator seal
- Base block
- End plate
- Fastening screw
- Assemble the Valve ramp on the Bracket with the Screw.
- Fit the Pneumatic hose and the Pneumatic hose.
- Make sure that no cables or pneumatic hoses have accidentally been removed. If necessary fit the pneumatic hoses (according to the pneumatic diagram) and the cables (according to the EM).

- Valve ramp
- Bracket
- Screw
- Pneumatic hose
- Pneumatic hose
- Fasten the bracket by tighten the Screw.
- Turn on the power supply.
- Turn on the air supply. Check that the Pressure gauge shows 630 kPa (6.3 bar).

- Screw
- Pressure gauge
Functional Description
The TTCU is connected to the TT/3 filling machine Pluto safety system and it communicates with the TT/3 filling machine control system using DeviceNet. The TTCU can be connected to two TT/3 filling machines, but can only supply cleaning/disinfection solution to one machine at the time.When cleaning/disinfection is selected on one of the TT/3 filling machines’ TPOP, the TTCU Pluto safety system sends a signal to the Pluto safety system in the other TT/3 filling machine stating that the TTCU is not idle. That signal is used to block the selection of the cleaning/disinfection on that TT/3 filling machine’s TPOP. The Pluto safety system also switches the TTCU DeviceNet between TT/3 filling machines.The TT/3 filling machine that has connection with the DeviceNet loop in TTCU can perform cleaning/disinfection, that means that the TTCU can be considered as one node that is shared between the TT/3 filling machines.For more information and procedures see chapter Electrical System.Electrical Cabinet - Check Residual Current Device
| Equipment Status | Program Step |
Hazardous voltage.Change the residual current device if it does not trip immediately.Electric shock will cause death or serious injury.
Before using the socket outlet always check the residual current device, see Section Residual Current Device - Check.Functional Description
The logger presents the conductivity, temperature, and flow of the cleaning solution supplied to the TT/3 filling machine on its monitor. As the TTCU can support two TT/3 filling machines, the logger also shows which of the two machines the unit supplies cleaning solution to.Measured Parameters
| Parameter | Unit |
| Conductivity | mS/Cm |
| Temperature | °C |
| Flow | m3 |
| Machine | 20XXX or 20YYY |
The measured parameters are recorded on the logger when the cleaning program is chosen on the TPOP, and the TTCU is in operation. The logger stores all of the measured parameters on its memory card.The memory card has enough room to record continuously for 15 months. The log from the logger can be used to diagnose the cleaning systems and to find the cause of any malfunction of the unit. The diagnosis can be done on a PC. The log files can be moved from the memory card to a computer, where an add-in for Microsoft Excel can be used to present the data in several different ways.Alarms
If the measured parameters are outside of the specified limits, a yellow alarm will be triggered.Logger - Set a Name for the Logger
| Equipment Status | Program Step |
- Enter the operator menu. See Procedure Logger - Enter the Operator Menu, on page Logger - Enter the Operator Menu.
- Press the Down key twice to step to the
Group 1 option. - Press the Enter key to accept the
Group 1 option and to open the Group Configuration window. 
- Down key
- Enter key
- Press the Enter key to accept the
Tag option. - Use the Down key, Up key, Left key , and Right key to step to and highlight the Del option.
- Press the Enter key several times to delete the text XXX in the Text box.
- Enter the TTCU machine number with underscores before and after the number. For example, if the machine number is 123 your enter: _123_. Use the following method:

- Down key
- Enter key
- Up key
- Left key
- Right key
- Del option
- Text box
- Next symbol set option
- Use the Down key, Up key, Left key, and Right key to step to the ok.
- Press the Enter key to accept the new logger name.
- Press the Menu key to open the Operator menu.
- Press the Down key once to step to the Common option.
- Press the Enter key to accept the
Common option and to open the Common Configuration window. - Use the Down key to step to and highlight the
Edit button by the text box for Instrument tag. - Press the Enter key to accept the
Instrument tag option. - Enter the TTCU machine number in the Text box according to Item Reference to Reference above.
- Use the Down key, Up key, Left key, and Right key to step to the ok.
- Press the Enter key to accept the new instrument tag.
- Press the Menu key to open the
Operator menu. - Use the Up key to step to the
Exit option. - Press the Enter key to accept the
Exit option. - Press the Enter key to accept the
Save As Current Configuration choice. - Press the Enter key to choose
Yes. - Press the Enter key to choose
Internal Storage and to save the new logger name.
Logger - Set TT/3 Machine Numbers for the Logger
| Equipment Status | Program Step |
- Enter the operator menu. See Procedure Logger - Enter the Operator Menu, on page Logger - Enter the Operator Menu.
- Press the Down key three times to step to the
CHANNEL 1.1-1.6 option. - Press the Enter key to accept the
Channel 1.1-1.6 option and to open the Channel list. 
- Down key
- Enter key
- Press the Down key three times to step to the
Channel 1.4 option. - Press the Enter key to accept the
Channel 1.4 option. - Use the Right key to step to the configuration tab
Digital I/P A4. - Use the Down key to step to and highlight the
Edit button by the text box for Digital OFF tag. - Press the Enter key to edit the text in the text box.
- Use the Down key, Up key, Left key, and Right key to step to and highlight the Del option.
- Press the Enter key several times to delete the text 20XXX in the Text box.

- Down key
- Enter key
- Right key
- Up key
- Left key
- Del option
- Text box
- Enter the TT/3 machine number. For example, if the machine number is 20012, enter “20012”. Use the following method:
- Use the Down key, Up key, Left key, and Right key to step to the OK.
- Press the Enter key to accept the TT/3 machine number.
- Use the Up key to step to the and highlight the
Edit button by the text box for Digital ON tag.Note: If there is only one machine installed on the site, remove the text in the text box. - Repeat item Reference to Reference.

- Down key
- Enter key
- Right key
- Up key
- Left key
- OK
- Press the Menu key to open the Operator menu.
- Use the Up key to step to the Exit option.
- Press the Enter key.
- Press the Enter key to accept the
Save As Current Configuration choice. - Press the Enter key to choose
Yes. - Press the Enter key to choose
Internal Storage and to save the TT/3 machine numbers. 
- Enter key
- Up key
Logger - Set Date and Time
| Equipment Status | Program Step |
- Enter the operator menu. See Procedure Logger - Enter the Operator Menu, on page Logger - Enter the Operator Menu.
- Press the Down key to step to the
Common option. - Press the Enter key to accept the
Common option. 
- Down key
- Enter key
- Use the Right key to step to the configuration tab Time.
- Press the Enter key to open the
Date and time window. - Use the Up key and the Left key to step to the and highlight the Edit button by the text box for
Date-Format tag. - Press the Enter key to open the
Date window. - Use the Up key or the Down key to highlight DD/MM/YY.
- Press the Enter key to set DD/MM/YY as date format.
- Press the Right key to step to and highlight the Edit button by the text box for
Time-Format tag. - Press the Enter key to open the
Time window. - Use the Up key or the Down key to highlight HH:MM:SS.
- Press the Enter key to set HH:MM:SS as time format
- Use the Down key, Up key, Left key, and Right key to step to and highlight the Edit Button by the text box for
Year tag. 
- Down key
- Enter key
- Right key
- Up key
- Left key
- Edit button
- Edit button
- Edit Button
- Press the Enter key to open the Year window.
- Press the Left key to highlight the Del option.
- Press the Enter key several times to delete the content of the text box.
- Enter a new value in the text box using the following method:
- Use the Down key, Up key, Left key, and Right key to step to Ok.
- Press the Enter key to accept the new value.

- Down key
- Enter key
- Right key
- Up key
- Left key
- Del option
- Ok
- Repeat item Reference to Reference for Month, Day, Hours, Minutes, and Seconds to enter a full date and time.
- Use the Down key, Up key, Left key, and Right key to step to and highlight OK.
- Press the Enter key to set the new date and time.
- Use the Left key to step to the configuration tab Set up.
- Press the Menu key to open the Operator menu.
- Use the Up key to step to the Exit option.
- Press the Enter key to accept the Exit option.
- Press the Enter key to accept the
Save As Current Configuration choice. - Press the Enter key to choose
Yes. - Press the Enter key to choose
Internal Storage and to save the setting. 
- Down key
- Enter key
- Right key
- Up key
- Left key
- OK
Logger - Remove the Memory Card
| Equipment Status | Program Step |
Fragile material.Never bend the memory card.The material of the memory card is brittle and it will brake if it is bent.
Damage from static electricity.Static electricity can damage the memory card. Remove any static energy by touching a grounded metal object before you touch the memory card. Never touch the gold connectors on the card.
Take the Memory Card Off-line
- Push the Menu key to open the
Operator menu. - Use the Down key or Up key to step to the
Setup option. - Push the Enter key to select the
Setup option. - Use the Down key or Up key to step to the
Off-line option. - Push the Enter key to select the
Off-line option. - Make sure that the Memory card icon changes colour from green to grey.

- Down key
- Up key
- Enter key
- Memory card icon
Remove the Memory Card from the Logger
Light sensitive material.Never place the card in direct sunlight.Direct sunlight can destroy the memory card.
- Unlock the Memory card door with the Key.
- Pull the Release catch and open the Memory card door.
- Press the button and remove the Memory card.
- Place the Memory card in an anti-static case when it is not in use.
- Close the Memory card door.

- Memory card door
- Key
- Release catch
- Memory card
Logger - Change the Battery
| Equipment Status | Program Step |
| Special Equipment | Renata CR2450N battery |
Damage from static electricity.Static electricity can damage the main board. Wear an anti-static strap or dismantle the unit on an anti-static workbench.
- Disconnect the power supply from the logger.
- Remove the jacking screw at the bottom of the logger, and pull the logger instrument out of its case.
- Remove the two Screw from the top cover, and then lift up (arrow) and remove the top cover.
- Remove the PCB locking bar.

- Screw
- PCB locking bar
Note: Make a note of the order in which you remove components. Assemble in the reverse order after changing the battery.- Remove the module cards as necessary to access the battery terminal. Often, you only need to remove the I/O card from Slot D.

- Slot D
Note: The logger uses a Renata CR2450N battery.Note: Make sure the positive terminal of the battery faces the rear of the logger, as shown in the illustration below.- Replace the Battery with a new one.
- Assemble the logger in the reverse order, and reconnect the power supply.
- Set the date and time. See Procedure Logger - Set Date and Time on page Logger - Set Date and Time.

- Battery
Logger - Install the Memory Card
| Equipment Status | Program Step |
Fragile material.Never bend the memory card.The material of the memory card is brittle and it will brake if it is bent.
Damage from static electricity.Static electricity can damage the memory card. Remove any static energy by touching a grounded metal object before you touch the memory card. Never touch the gold connectors on the card.
Install the Memory Card in the Logger
- Unlock the Memory card door with the Key.
- Pull the Release catch and open the Memory card door.
- Carefully insert the Memory card into the logger.
- Close the Memory card door.

- Memory card door
- Key
- Release catch
- Memory card
Bring the Memory Card On-line
Note: The logger brings the memory card on-line automatically.- Make sure that the Memory card icon changes colour from grey to green. If necessary, perform item Reference to Reference.
- Press the Menu key to open the Operator menu.
- Use the Down key or Up key to step to the
Setup option. - Press the Enter key to accept the
Setup option. - Use the Down key or Up key to step to the
On-line option. - Press the Enter key to select the
On-line option. - Make sure that the Memory card icon changes colour from grey to green.

- Down key
- Up key
- Enter key
- Memory card icon
Logger - Load Data from the Memory Card to a PC
| Equipment Status | |
| Special Equipment | PC Compact Flash card reader |
- Place the memory card in the memory card reader of the PC.
- Use the explorer to open the memory card drive on the PC.Note: Do not open the SM1000 files.
- Copy the folder named SM1000 from the memory card to a suitable location on the PC.
- Eject the memory card from the PC.
Logger - Install Datamanager Software on the PC
Install
- Insert the Datamanager installation CD into the CD-drive.Note: You may be able to find a later version of the software on the ABB web site.
- Click
Install DataManager Software (Excel 2000, 2002, 2003 & XP). - Click
Next. - Choose
I accept the terms in the license agreement and click Next.
- Enter a User Name and a Organization and click
Next. - Click
Next to accept the installation folder. - Click
Next to start the installation.Note: The installation may take a few minutes. Go to the next step when the program is installed. - Read the text in the window and then click
Next. - Click
Finish to finish the installation.
Activate
- Start Microsoft Excel.
- Select
Add-ins in the Tools menu to open the Add-in window. - Select
Datamanager by checking the check box next to it. If Datamanager can not be selected from the list, do item Reference to Reference.
- Click
Browse and navigate to: . - Double-click on the
Datamanager Add-in file. The add-in will now be activated in Microsoft Excel. - Click
ok in the Add-in window. A new Datamanager tool bar appears in Microsoft Excel.
Logger - Open and View Data in Microsoft Excel
| Equipment Status | |
| Special Equipment | PC |
- Open Microsoft Excel.
- Click the Open Binary File.
- Click the top Browse....
- Browse to where you placed the binary files from the logger card.
- Choose the binary file that you want to open and click
Open. - If you want to open more than one file at the same time, click the next
Browse... button and do item Reference to Reference again. You can open up to 12 files at a time. - Check the Check box next to the file or files that you want to open.
- Set the time span of the files that you want to open with the Start time slide bar and the End time slide bar. Only the time between the start and end time will be shown when you open the file.
- Click the Create spreadsheet button.

- Open Binary File
- Browse...
- Check box
- Start time slide bar
- End time slide bar
- Create spreadsheet button
- Click the View chart.
- Choose a start and end time in the
Chart Data Selection window. - Click Ok to create a graphic chart of the data.

- View chart
- Ok
Logger - Load Configuration File to the Memory Card
| Equipment Status | |
| Special Equipment | PC |
Fragile material.Never bend the memory card.The material of the memory card is brittle and it will brake if it is bent.
Damage from static electricity.Static electricity can damage the memory card. Remove any static energy by touching a grounded metal object before you touch the memory card. Never touch the gold connectors on the card.
- Place the memory card in the memory card reader of the PC.
- Use the explorer to open the memory card drive on the PC.
- Place the DVD with the configuration file in the DVD reader of the PC.
- Use the explorer to open the DVD and locate the configuration file
TTCU_config_XX.cfg.Note: XX stands for the version of the configuration file. Always use the configuration file with the highest version number if there are more than one to choose from. - Create a folder, named SM1000, on the memory card.
- Copy the configuration file
TTCU_config_XX.cfg from the PC to the folder SM1000 on the memory card.Note: If the configuration file is not put in the folder SM1000, the file will not be reached when the configuration is to be loaded to the logger. - Remove the memory card from the PC.
Logger - Enter the Operator Menu
| Equipment Status | Program Step |
- Press Menu key to open the
Operator menu. - Press the Down key once to step to the
Configuration option. - Press the Enter key to accept the
Configuration option. - Press the Enter key to accept
Operator 1. - Use the Down key, Up key, Left key, and Right key to step to and highlight a number, letter or symbol.
- Enter the password 1234. Use the Enter key to enter a highlighted number, letter, or symbol.
- Use the Down key, Up key, Left key, and Right key to step to the OK.
- Press the Enter key to accept the password.

- Down key
- Enter key
- Up key
- Left key
- Right key
- OK
- Press the Enter key to accept
Edit Current Configuration and to open the System Configuration window. - Press the Menu key to open the
Operator menu.
Functional Description
The logger presents the conductivity, temperature, and flow of the cleaning solution supplied to the TT/3 filling machine on its monitor. As the TTCU can support two TT/3 filling machines, the logger also shows which of the two machines the unit supplies cleaning solution to.Measured Parameters
| Parameter | Unit |
| Conductivity | mS/Cm |
| Temperature | °C |
| Flow | m3 |
| Machine | 20XXX or 20YYY |
The measured parameters are recorded on the logger when the cleaning program is chosen on the TPOP, and the TTCU is in operation. The logger stores all of the measured parameters on its memory card.The memory card has enough room to record continuously for 15 months. The log from the logger can be used to diagnose the cleaning systems and to find the cause of any malfunction of the unit. The diagnosis can be done on a PC. The log files can be moved from the memory card to a computer, where an add-in for Microsoft Excel can be used to present the data in several different ways.Alarms
If the measured parameters are outside of the specified limits, a yellow alarm will be triggered.Logger - Set a Name for the Logger
| Equipment Status | Program Step ZERO |
- To display the Operator menu, press Main menu.
- Press Configuration.
- Press Confirm.
- Press Confirm. No password is required in the Text box.


Main menuConfigurationConfirm- Text box
Confirm
- Enter the
Tag menu by pressing in sequence: 
Edit ConfigurationCommonEdit- Text box
Confirm
- Enter the
Recording tag menu by pressing: - Press Return/Cancel, Return/Cancel, and Return/Cancel.

Return/CancelGroupsGroup 1Edit- Text box
ConfirmReturn/CancelReturn/CancelReturn/Cancel
- Press Apply Changes and then Confirm.
- Save the configuration file.

Apply ChangesConfirm
Logger - Set TT/3 Machine Numbers for the Logger
| Equipment Status | Program Step |
- Press the Main menu button to display the
Operator menu. - Press the Configuration icon in the
Operator menu. - Press the Confirm button in the
Select operator menu. - Enter the password
1234 in the Text box and then press the Confirm button to accept the password. 

Main menu buttonConfiguration iconConfirm button- Text box
Confirm button
- Press in sequence the:
- Step to the Channel 1.04 with the Arrow button.
- Press the Edit button to edit the
Digital on tag. - Enter the TT/3 machine number in the Text box for the
Digital on tag.For example, if the machine number is M20011 enter: M20011 and press the Confirm button. - Press the Edit button to edit the
Digital off tag. - Enter the TT/3 machine number in the Text box for the
Digital off tag and press the Confirm button.Note: If there is only one machine installed on the site remove the text in the text box. 

Edit Configuration buttonChannels iconGroup 1 Channels iconAnalog I/P A1 tabArrow buttonEdit button- Text box
Confirm buttonEdit button- Text box
Confirm button
- Press the Return/Cancel button, Return/Cancel button, and Return/Cancel button

Return/Cancel buttonReturn/Cancel buttonReturn/Cancel button
- Press the Apply Changes button and then the Confirm button.

Apply Changes buttonConfirm button
Logger - Set Date and Time
| Equipment Status | Program Step |
- Press the Main menu button to display the
Operator menu. - Press the Configuration icon in the
Operator menu. - Press the Confirm button in the
Select operator menu. - Enter the password
1234 in the Text box and then press the Confirm button to accept the password. 

Main menu buttonConfiguration iconConfirm button- Text box
Confirm button
- Enter the
Date and Time menu by pressing in sequence the: 
Edit Configuration buttonCommon iconTime tabEdit buttonConfirm button
- Change the date and time by pressing respective Edit button in the red dashed rectangle.Enter the value in the Text box and press the Confirm button.
- Change the format by pressing respective Edit button in the green dashed rectangle.Select format in the
Date menu respective Time menu and press the Confirm button respective Confirm button. - Press the Confirm button in the
Date and time menu. 
Edit button- Text box
Confirm buttonConfirm buttonConfirm buttonConfirm button
- Press the Return/Cancel button and the Return/Cancel button.
- Press the Apply Changes button.

Return/Cancel buttonReturn/Cancel buttonApply Changes button
Logger - Load Data from The Memory Card to a PC
| Equipment Status | |
| Special Equipment | PC Compact Flash card reader |
- Place the memory card in the memory card reader of the PC.
- Use the explorer to open the memory card drive on the PC.Note: Do not open the RVG200 files.
- Copy the folder named RVG200 from the memory card to a suitable location on the PC.
- Eject the memory card from the PC.
Logger - Install Datamanager Software on the PC
| Special Equipment | PC Datamanager software |
Install
- Insert the Datamanager installation CD into the CD-drive.Note: You may be able to find a later version of the software on the ABB homepage.
- Click the
setup.exe application.
- Click the
Next button.
- Select installation folder and click the
Next button.
- Confirm the installation and click the
Next button to start the installation.
- When the installation is complete click the
Close button to exit.
- Start the
DataManager by double-click symbol on the screen.
Logger - Upload The Configuration From The Memory Card to The Logger
- Press the Main menu button to display the
Operator menu. - Press the Configuration icon in the
Operator menu. - Press the Confirm button in the
Select operator menu. - Enter the password
1234 in the Text box and then press the Confirm button to accept the password. 

Main menu buttonConfiguration iconConfirm button- Text box
Confirm button
- Press the Open Configuration button in the
Operator 1 menu. - Select the
SD Card in the Item list and press the Confirm button. - Select the
TTCU_RVG200_XX.cfg file in the Item list and press the Confirm button.Note: XX stands for the version of the configuration file. Always use the configuration file with the highest version number if there are more than one to choose from. - Press the Return/Cancel button in the
System Configuration menu. 
Open Configuration button- Item list
Confirm button- Item list
Confirm buttonReturn/Cancel button
- Press the Apply Changes button and then the Confirm button.

Apply Changes buttonConfirm button
Functional Description
The TTCU can supply cleaning solution or disinfection solution to two different TT/3 filling machines. The valve unit divert the liquid to one of the TT/3 filling machines. The valve unit consist of the pressure side valve unit and the return side valve unit.Note: See also the Section on page .
The illustration shows the non USA/Canada variant.
Valve Group - Check Ball Valve
| Equipment Status | Program Step |
Hot parts.Pipes and components in the Tetra Top Cleaning Unit can cause burn damages. Before service, make sure that the pipes are cool before performing this procedure.
- During cleaning or disinfection of the hygiene chamber make sure that the Ball valve and the Ball valve is not leaking.

- Ball valve
- Ball valve
- Ball valve
- Ball valve
Valve Group - Set Switch
| Equipment Status | Program Step |
- Set the distance A between the Proximity switch and the Flange.

A (mm) = 0.5 ± 0.1
- Proximity switch
- Flange
Valve Unit - Change Ball Valve Seals
| Equipment Status | Program Step Program Step |
| Consumables | Alkali solution (Manual Cleaning) |
Remove Valve Groups
Remaining hazardous media. The system could contain hazardous media under pressure. Before service, make sure that the valves and the pipes are drained and pressureless. Use protective safety equipment: safety glasses, protective gloves, and an apron.
Hot parts. Pipes and components in the Tetra Top Cleaning Unit can cause burn damages. Before service, make sure that the pipes are cool before performing this procedure.
- Remove the Pneumatic hose.
- Remove the proximity switch Cable.
Heavy equipment.Handle the valve with care and make sure that you take precautions to handle the weight.The valve is heavy and can cause personal injuries and damage to equipment.
Remove the Valve by removing the Clamp and the Gasket, and place the valve on a clean suitable working area.Note: The other valves are removed in a similar way.
- Pneumatic hose
- Cable
- Valve
- Clamp
- Gasket
Overhaul Valve Groups
Remaining media.Risk of pressurised fluid. Before separating the valve from the pipes, ensure there is no pressure or fluid in the system.
- With the valve in open position, remove three of the Screw and the Nut loosen the forth Screw.
- Swing out the Valve body from the Valve end.Note: Be careful, not to damage or scratch the ball.
- Close the Ball and remove the Seat ring, the Ball and the Seal.

- Screw
- Nut
- Valve body
- Valve end
- Ball
- Seat ring
- Seal
- Loose the Nut and remove washers etc. below it.
- Remove the Spindle and the Spindle gasket.
- Replace all parts included in the seal kit.
- Clean the remaining parts.
- Assemble in the reverse order. Tighten the Nut and the Screw.
- Check the function of the valve.

- Screw
- Nut
- Spindle
- Spindle gasket
Diaphragm Valve - Install
| Equipment Status | Program Step step zero |
- Remove the Nut from the Valve.
- Remove the Rod.
- Install the Mounting kit.
- Install the Position indicator.

- Nut
- Valve
- Rod
- Mounting kit
- Position indicator
Position Indicator - Set
| Equipment Status | Program Step step zero |
- Pull the Cover up, approximately 2mm.
- Turn the Cover to the left to set the position indicator in the Programming Mode. The position indicator flashes red and green alternately when it is in the programming mode.
- Activate the Actuator to OPEN and CLOSED position two times.
- Turn the Cover to the right and press down. The position indicator is now back in the Operating Mode.Note: The position indicator turns red when activated, and green when deactivated.
- After the position indicator has been set, activate the Actuator to OPEN and CLOSED position two times, to make sure that it indicates open and closed function.Note: After changing the diaphragm in the actuator, new programming is necessary.

- Cover
- Actuator
Description
This chapter contains the maintenance procedures for the Granulate Supply Unit (GSU). The functional description on page Functional Description provides a technical overview of the GSU.Functional Description
See OM for more information about the GSU such as Control Panel, and alarms and troubleshooting.The granulate supply unit (GSU) is a supply unit to the filling machine that consists of a Central granulate unit and a Granulate container. The Granulate container is available in different sizes. Also a Granulate hopper is needed to balance the distribution. The Central granulate unit and the Granulate container can be placed up to 50 m from the filling machine, while the Granulate hopper is connected to the filling machine.The GSU provides the filling machine with a vacuum pressure allowing the filling machine to collect granulate. One GSU can serve up to eight filling machines at the same time.
- Central granulate unit
- Granulate container
- Granulate hopper
When a signal is transmitted from a filling machine to the GSU, the fan starts. A vacuum Valve shifts at the same time the fan starts, changing the direction of the airflow to clean the Filter. The valve shifts back a few moments later building up a vacuum. During the automatic cleaning of the Filter, some granulate and dust is gathered in the Plastic bag below the Filter.
- Valve
- Filter
- Plastic bag
GSU - Clean Filter
See OM for more information about the GSU such as the control panel, alarms, and troubleshooting.Risk of crushingBe careful when working near it.The fingers can be crushed when removing the
Tension ring.
Remove the Tension ring.- Lift the Lid and the Valve housing to access the Filter.
- Clean the Filter using a vacuum cleaner.Note: If the socket outlet inside the electrical cabinet in the GSU is used, the residual current device must first be checked, see section on page .
- Assemble in the reverse order.

- Tension ring
- Lid
- Valve housing
- Filter
GSU - Change Filter
| Equipment Status | Program Step |
See OM for more information about the GSU such as the control panel, alarms, and troubleshooting.Risk of crushingBe careful when working near it.The fingers can be crushed when removing the
Tension ring.
Remove the Tension ring.- Lift the Lid and the Valve housing to access the Filter.
- Change the Filter.
- Assemble in the reverse order.

- Tension ring
- Lid
- Valve housing
- Filter
Description
This chapter contains the maintenance procedures general for the filling machine. It also contains additional information for example a list of templates and tools, laminated documents and so on.Tightening Torque for Screw Joints
Note: Apply the required prestressing force to a screw joint reinforcement, tighten screws, nuts, and so on, according to the tightening torque table, unless otherwise stated.Carbon steel and Alloy steel screw with standard pitchTable values apply to untreated lubricated screw connections when using a torque wrench or tenacious screw/nut driver with torque control. Max torque spread on tool is +/-5%.| Mechanical properties according to ISO 898-1 | Property class |
| Thread Size | Pitch | 8.8 | 12.9 |
| (mm) | Torque (Nm) |
| M4 | 0.7 | 3.9 | 4.9 |
| M5 | 0.8 | 5.7 | 9.7 |
| M6 | 1 | 9.8 | 17 |
| M8 | 1.25 | 24 | 40 |
| M10 | 1.5 | 47 | 79 |
| M12 | 1.75 | 81 | 136 |
| M14 | 2 | 128 | 217 |
| M16 | 2 | 197 | 333 |
| M18 | 2.5 | 275 | 463 |
| M20 | 2.5 | 385 | 649 |
Stainless screw A2-A4To pretension stainless and acid-resistant screw connections, effective lubrication is required. Otherwise the threads will seize. The values in the table refer to waxed products. Lubrication with molybdenum sulphide (MoS2) gives a similar friction ratio to wax, which means that the table can be used. Table values apply to screw connections when using a torque wrench or tenacious screw/nut driver with torque control. Max torque spread on tool is +/-5%.Apply the required prestressing force to a screw joint reinforcement, tighten screws, nuts, and so on, according to the tightening torque table, unless otherwise stated.| Mechanical properties according to ISO 3506-1 | Property class |
| Thread Size | Pitch | 70 | 80 |
| (mm) | Torque (Nm) |
| M4 | 0.7 | 2 | 2.7 |
| M5 | 0.8 | 4.1 | 5.4 |
| M6 | 1 | 7 | 9.3 |
| M8 | 1.25 | 17 | 22 |
| M10 | 1.5 | 33 | 44 |
| M12 | 1.75 | 57 | 76 |
| M14 | 2 | 91 | 121 |
| M16 | 2 | 140 | 187 |
| M18 | 2.5 | 195 | 260 |
| M20 | 2.5 | 273 | 364 |
Tightening Torque - Hydraulic Connections
Give a hydraulic connection the required tightening torque according to the tightening torque tables below if nothing else is stated.Note: The values below are valid for steel connections (with surface treatment) and with connecting parts made of steel.| Standard Tightening Torque Metric Thread |
| Series | Pipe diameter | Metric Thread ISO | MA (Nm) |
| L | 681012151822283542 | M 10 x 1M 12 x 1.5M 14 x 1.5M 16 x 1.5M 18 x 1.5M 22 x 1.5M 26 x 1.5M 33 x 2M 42 x 2M 48 x 2 | 2530508090160285425600800 |
| S | 681012141620–253038 | M 12 x 1.5M 14 x 1.5M 16 x 1.5M 18 x 1.5M 20 x 1.5M 22 x 1.5M 27 x 2–M 33 x 2M 42 x 2M 48 x 2 | 356095120170190320(250)*500600800 |
*) Valid for connections with soft gaskets. The “S” series must be used for type RI.| Standard Tightening Torque Pipe Thread |
| Series | Pipe diameter | Pipe Thread | MA (Nm) |
| L | 681012151822283542 | G 1/8 AG 1/4 AG 1/4 AG 3/8 AG 1/2 AG 1/2 AG 3/4 AG 1 AG 1 1/4 AG 1 1/2 A | 25505080160105220370600800 |
| S | 681012141620–253038 | G 1/4 AG 1/4 AG 3/8 AG 3/8 AG 1/2 AG 1/2 AG 3/4 A–G 1 AG 1 1/4 AG 1 1/2 A | 6060110110170140320(250)*380600800 |
*) Valid for connections with soft gaskets. The “S” series must be used for type RI.Screw Joints Lubrication
Risk of personal injury.In the hydrogen peroxide system, do not use any other grease than the one stated.Risk of explosion in the hydrogen peroxide system.
It is common practice to lubricate all screw unions with anti-seize TP No. 344417-0000 or 344418-0000.Risk of equipment damage.When assembling a peroxide system, use PTFE grease (TP No. 1607031-0000) for all threaded gland fittings. Make sure that no grease enters the system through pipes, valves, and so on. Before assembling, lubricate the positions marked with an arrow using grease.
Locate a Spare Part Number
Locate a Spare Part Number. Alternative 2.a) Go to the chapter that contains the part you want to locate.b) On the main group illustration, look for the Machine subgroup that contains the part you are looking for. Note the Position number and go to the list page that follows the illustration.
- Machine subgroup
- Position number
c) Locate the Position number in the Pos column. Click on the link to the corresponding Page number in the Page No column.Note: If there is more than one page number listed, click on the link of the first page number.
- Position number
- Page number
d) Go to the list page that follows the illustration.e) If there are one or more Variant grouping in the list page, they will appear first. Check which variant applies to the part that you looking for, and click on the Page number of the corresponding illustration.f) If there are no variant grouping in the list page, go to item j).
- Variant grouping
- Page number
g) On the subgroup illustration, look for the Part or subgroup that contains the part you are looking for. Note the Position number and go to the list page that follows the illustration.Note: If there are multiple drawings, the list page after all drawings, with the exception of the first one, will contain a cross-reference back to the list page that appears after the first drawing.
- Part or subgroup
- Position number
h) Locate the Position number in the Pos column. Click on the link to the corresponding Page number in the Page No column.
- Position number
- Page number
i) On the subgroup illustration, look for the Part or subgroup that contains the part you are looking for. Note the Position number or reference designation (in this case, reference designation), and go to the list page that follows the illustration.
- Position number or reference designation
- Part or subgroup
j) Locate the Position number or reference designation (in this case, reference designation) in the Pos column.k) Annotate the corresponding Part number in the Part No column, and the corresponding Part description in the Description column.
- Position number or reference designation
- Part number
- Part description
General Procedures
The following procedures are at a general level.Turn Off one Side of the Machine
| Equipment Status | Program Step |
| Consumables | Excenter handle TP No. 2681250-0000 Security Strip |
If problems with broken machine equipment or no-resettable alarms occur on one side of the machine, this side can be shutdown and the production can continue on the other side. Some machine parts are driven by the same motor on S1 and S2. These machine movements will still continue on the side that is shutdown.To avoid mechanical wear and damage on machine parts, these parts must be disconnected mechanically before the side is shutdown from the operators panel. Affected parts are in Carton Section and Package Section.Mechanical Actions in Carton Section
• To avoid the Stripper to strike into the idle Mandrel.• To avoid the Pusher piston to strike into the Inner tool on the Mandrel wheel.

- Stripper
- Mandrel
- Pusher piston
- Inner tool
- Mandrel wheel
- Remove the Stripper from the LFU by removing the four Screw.
- Dismount the Safety clutch by removing the Screw.
- Secure the Safety clutch with a security strip in a position where it cannot hit the Link arm.

- Stripper
- Screw
- Safety clutch
- Screw
- Link arm
Mechanical Actions in Package Section
• To prevent the Bottom seal lift from wearing down the Cassette link.• Release the Fill lift.
- Bottom seal lift
- Cassette link
- Fill lift
- Attach the Excenter handle to the Bottom seal lift.
- Raise the handle up to allow the Cassette link to pass by.

- Bottom seal lift
- Cassette link
- Excenter handle
- Remove the Fork by removing the Screw.

- Fork
- Screw
Operators Panel - Turn off one side
The following instructions describes machine side 1. The procedure is similar for side 2.- Connect a keyboard and press F4 to open the
Technical Menu window. - Press 1/2.Note: It is only possible to turn off one side at a time.

- 1/2
- Press Enable/Disable Carton Section S1 to select Carton Section for side 1.
- Press Disable Carton Section S1 to turn off Carton Section side 1.Note: Make sure the machine units for Carton Section are secured, see on page .

- Enable/Disable Carton Section S1
- Disable Carton Section S1
- Press Enable/Disable Package Section S1.
- Press Disable Package Section S1 to turn off Package Section Side 1.Note: Make sure the machine units for Package Section are secured. See on page .

- Enable/Disable Package Section S1
- Disable Package Section S1
The following window is shown. Side 1 is turned off. All movements are disabled.- Press Exit.
- Press
Save to confirm.Note: It is not possible to change machine status for side 1. - Disconnect the keyboard.
- Step up side 2 to PRODUCTION.

- Exit
Operators Panel - Turn on one side
- Remove the mechanical fixing units in Carton and Package section, see Mechanical Actions in Carton Section and Mechanical Actions in Package Section.
- Connect a keyboard and press F4 to open the
Technical Menu Window. - Press 1/2.Note: The Package Section must be turned on before the Carton Section.

- 1/2
- Press Enable/disable Package section S1 and press Enable Package section S1.

- Enable/disable Package section S1
- Enable Package section S1
- Press Enable/disable Carton section S1 and press Enable Carton section S1.

- Enable/disable Carton section S1
- Enable Carton section S1
The following window appears.- Press Exit.
- Press
Save. Both sides are now ready to step up. - Disconnect the keyboard.

- Exit
Pipe Gaskets - Change
Used in TT/3, TR, and A6 | Equipment Status | Power must be turn OFF. Air must be turn OFF. Steam must be turn OFF. Water must be turn OFF. Program Step Step Zero |
| Consumables | Gasket 1 inch TP No. 342850-0203 Gasket 1.5 inch TP No. 342850-0204 Gasket 2 inch TP No. 342850-0205 Gasket 2.5 inch TP No. 342850-0206 Gasket 3 inch TP No. 342850-0207 |
- Open the Clamp by loosening the Nut.
- Remove the Clamp.
- Remove the old Gasket.
- Remove any rubber residue from the Flange.
- Install the new Gasket. Make sure that it is centred on the Flange.
- Make sure that the Flange are aligned to avoid leakage.
- Install and tighten the clamp.Note: Do not over-tighten the clamp.

- Clamp
- Nut
- Gasket
- Flange
Touch-up Paint - Apply
| Equipment Status | Power must be turn OFF.
|
| Special Equipment | Painting kit TP No. 2758723-0000 |
Use this painting kit when the machine body have been damaged in the enamel layer, or damaged in both enamel and the primer layer.The content of the painting kit is described in the table below.| Material List | Qty | Data | No. | Volume (ml) |
| Primer | 2 | Paint No. S12 | 90299-0057 | 30 |
| Enamel Paint | 2 | Paint No. S10 | 90299-0063 | 30 |
| Hardener | 3 | | 90299-0059 | 30 |
| Thinner | 3 | Akzo Nobel 40l | | 30 |
| Brush | 3 | Flat 5x15 mm | 776300-0101 | |
| Product Data Safety Sheet | 1 | Swedish | | |
| Product Data Safety Sheet | 1 | English | | |
| Drawing | 1 | | | |
How to Use
Risk of personal injury.Read and follow the safety precautions in the Product Safety Sheets before use.
- Clean the damaged surfaces that are to be painted with thinner.
- If necessary, protect surrounded surfaces.
- Mix two parts of the primer with one part of the hardener.
- Paint the surfaces and let it dry for a minimum of twotofourhours at a temperature of 20°C (68°F). The drying time increases if the temperature is lower.
- Mix one part enamel paint with one part of hardener.
- Paint the surfaces and let it dry for a minimum of twotofourhours at a temperature of 20°C (68°F). The drying time increases if the temperature is lower.Note: The paint takes 12 to 24 hours to fully harden at a temperature of 20°C (68°F). The drying time increases if the temperature is lower.
Power Failure - Start Up
| Equipment Status | Power must be turn ON.
|
Description
The TPOP restarts and the window below appears:- after the first startup of the machine.
- after the power has been cut off.
- if any of the PLC has been stopped.
The upper part of the window serves as a confirmation for the operator/technician. It confirms that the volume washers in the cassettes are positioned as stated in respectively text boxes. See Volume Change Mechanism - Check on page Volume Change Mechanism - Check for more information.The lower part of the window serves as a remainder to check that the positions of the servomotors are OK. The box can be ticked before or after the positions are checked. The reason that the positions have to be checked is that the shown axes cannot perform their homing automatically and have to be manually checked.
Start-up - Check Values
• If a motor has been changed, the position of the motor has to be reset. See section Start-up - Set Values. • If no motor has been changed, continue with the next step.- Connect a keyboard and press F4. The
Technical Menu window opens. - Select Servo Technical Window.

- Servo Technical Window
The following window appears. Check the real positions of the axles, according to following procedures:- Curve Unit:
- Check the position on the scale mounted on the Curve Unit.
- Confirm that the Position value TPOP shows the same value.
- Mandrel wheel:
- Turn the mandrel wheel to the indexed position as shown on the illustration on previous page.
- Confirm that the Position value TPOP shows an angle of 0° (zero) or 90°.
- Cassette conveyor:
- Inch the conveyor to the indexed position, (the cassettes are pointing towards the mandrel wheel).
- Confirm that the Position value TPOP shows an angle of 0° (zero) or 45°.
- If any of the servo motor position values are incorrect, see section Start-up - Set Values.
- Press
Exit. - Press
Save. 
- Position value TPOP
Start-up - Set Values
- Curve Unit:
- Mandrel wheel:
- Cassette conveyor:
CIP Concentration of Cleaning Solution
The following instructions describe how to check the concentration of detergent solutions used in CIP. The check is made either by measuring the electrical conductivity of the detergent solution or by using the titration method.CIP Concentration of Cleaning Solution – Check Using Electrical Conductivity Method (Technician)
| Equipment Status | Program Step |
| Special Equipment | Soft cloth Open vessel (Ø 150 mm) |
Electrical conductivity depends on the temperature and increases when temperature rises due to increased molecular motion.In the conductivity meter, the temperature compensation is done automatically so the measurement is accurate regardless of the temperature of cleaning solution.The measured electrical conductivity is related to the concentration in a calibration curve. The illustration shows the conductivity for the three most common cleaning chemicals as a function of concentration at 25°C.
Conductivity versus concentration at 25°C
Hazardous substances.Contact with chemicals could be hazardous to your health. Wear safety glasses and protective gloves when removing the conductivity sensor from the tank.
- Collect a sample of the alkali cleaning solution that is used during CIP.
- Remove the Conductivity meter from the TTCU tank by removing the Clamp and the Gasket.
- Rinse the Sensor thoroughly with plenty of water.
- Use a clean soft cloth to wipe off the sensor.
- Use the open vessel for the sample of cleaning solution and immerse the conductivity sensor in the sample.
- Make sure that the sensor is submerged completely in the solution.
- Make sure that the sensor is placed in the middle of the container, minimum 15mm from the edge.

- Conductivity meter
- TTCU tank
- Clamp
- Gasket
- Sensor
- Read the conductivity and record it.
- Rinse the sensor thoroughly with plenty of water.
- Use a clean soft cloth to wipe off the sensor.
- Repeat ItemReference, and Reference to Reference for the acid solution.
- Assemble the Conductivity meter and tighten the Clamp. Make sure that the Sensor is correctly positioned. The orientation arrow on the sensor must point downward.

- Conductivity meter
- TTCU tank
- Clamp
- Gasket
- Sensor
CIP Concentration of Cleaning Solution – Check Using Titration Method (for Pure Chemicals Such as Sodium Hydroxide and Nitric Acid) (Laboratory Assessment)
| Special Equipment | Titration burette 10ml pipette Beaker |
| Consumables | Hydrochloric acid (HCl) Sodium hydroxide (NaOH) Phenolphthalein 5% solution (alcohol based) |
In titration, the neutralisation reaction between an acid and a base, is utilised. A certain volume of the test solution (for example, nitric acid solution) is metered into a beaker. A titre solution (for example, sodium hydroxide solution of a known concentration) is added to the test solution until it becomes neutral. An indicator is added to the test solution to determine when the solution is neutral. Phenolphthalein indicator changes colour about pH7 and is therefore commonly used for acid/base titration.The test solution concentration can be calculated based on the titrant volume that is used, titrant concentration, and test solution volume.The test solution concentration can also be obtained by using titration diagrams.Titration of NaOH, HNO3 and H3PO4 Solutions
| Test solution | 10ml |
| Titre Solution | 0.1 mole/l or 1 mole/l HCl for an alkaline solution0.1 mole/l NaOH for an acid solution |
| Indicator | Phenolphthalein 5% solution (alcohol based) |
For recommended concentrations, see Section Chemicals for Cleaning and Disinfection.- Collect a 10ml sample of the alkali or acid cleaning solution that is used during CIP.
- Add three to five drops of the indicator solution to the test solution.
- Titrate with the titre solution until a colour change is seen.The colour changes from colourless to pink for an acid solution.The colour changes from pink to colourless for an alkaline solution.
- Calculate the concentration using the information in Sections Calculation or use the Titration Diagrams.
Calculation
- NaOH-concentration = x = the volume, in ml, of 0.1mole/l HCl used to obtain a colour change, when 10ml NaOH solution is titrated.
- NaOH-concentration = y = the volume, in ml, of 1mole/l HCl used to obtain a colour change, when 10ml NaOH solution is titrated.
- HNOz = the volume, in ml, of 0.1mole/l NaOH used to obtain a colour change, when 10ml HNO3 solution is titrated.
- Hv = the volume, in ml, of 0.1mole/l NaOH used to obtain a colour change, when 10m1 H3PO4 solution is titrated.
Titration Diagrams

Determination of NaOH concentration using 1 mol/l HCl

Determination of NaOH concentration using 0.1 mol/l HCl

Determination of HNO3 concentration using 0.1 mol/l NaOH

Determination of H3PO4 concentration using 0.1 mol/l NaOH
Air Service Tool Description
| Special Equipment | TP No. 3488500-0100 |
General Description
The air service tool is meant to be used when testing functions, checking for leakage, or performing adjustments that require pressurised air.
Function
- Make sure that the Incoming air switch is in the closed position.
- Connect the Incoming air connection on the air service tool to the Service connection on the main air ramp.
- Open the Valve on the main air ramp.

- Incoming air switch
- Incoming air connection
- Service connection
- Valve
- Connect the Left hose and the Right hose to the air consumer.
- Use the Left/right-switch to choose which of the hoses to activate.
- Slowly open the Incoming air switch to activate the air consumer.
- After using the air service tool, slowly close the Incoming air switch.
- Close the Valve on the main air ramp.
- Open the Incoming air switch to let out the remaining air.

- Incoming air switch
- Valve
- Left hose
- Right hose
- Left/right-switch
Pneumatic Valves - Manual Override
| Equipment Status | Program Step STEP ZERO |
Moving equipment parts.Be careful when working with the air cylinder.Risk of crushing.
Valid for Mecman
- Use the Valve Guide, TP No. 3520946-0000, to press the manual override button on the Pilot Valve. The valve is now locked in active position.
- To deactivate the valve, remove the Valve Guide from the Pilot Valve.

- Valve Guide
- Pilot Valve
Valid for Festo VUVG-B18
- Press and turn the Manual Override Button on the valve to the right to lock it in active position.
- To deactivate the valve, turn the Manual Override Button to the left.

- Manual Override Button
Valid for Festo MPA-C-VI
- Remove the Cover of the valve.
- Press and turn the Manual Override Button on the valve to the right to lock it in active position.
- To deactivate the valve, turn the Manual Override Button to the left.
- Put back the Cover when finished.

- Manual Override Button
- Cover
Consumables Tetra Top TT/3
Lubricants
Risk of personal injury.Always follow the manufacturer's instructions for handling chemical products.Certain lubricants can cause injury if they come into contact with the eyes, skin, mucous membranes, or clothing.
The two tables, Reference and Reference, list only a selection of lubricants with their respective designations.Lubricant specifications may be ordered from:Tetra Pak Technical Service AB,Ruben Rausings gataSE-221 86 LUND,Sweden Note: If there is need for more information regarding for example what kind of or how much oil a specific gear contains, see the chapter for the actual module.| Food Grade Lubricants Valid from machine 63202/20067 and machines with UK Food Grade Lubricants TT3, Kit No 3355833-0100For other machines, see the table Reference. |
| TP Part No.(used when ordering from TetraPak) | Lubricant Type | Example |
| Supplier | Product Designation |
| 90606-4796 (380 g) | Pneumatic Grease | Shell | AeroShell Grease 22 |
| 344407-0000Reference for purchasing:344407-0285 (45 g)344407-0591 (400 g)344407-0037 (1 kg)344407-0177 (25 kg) | Lubrication Grease | Klüber | Klübersynth UH1 14-151 |
| 344410-0000Reference for purchasing:344410-0764 (5 l)344410-0766 (20 l) | Gearbox Oil | Klüber | Klüberoil 4 UH1-68N |
| 344417-0000Reference for purchasing:344417-0213 (60 g)344417-0594 (500 g)344417-0046 (600 g) | Sliding Agent Anti Seize <120°C | Klüber | Klüberpaste UH1 84-201 |
| 344418-0000Reference for purchasing:344418-0319 (80 g)344418-0589 (600 g) | Sliding Agent Anti Seize >120°C | Klüber | Klüberpaste UH1 96-402 |
| 344443-0000Reference for purchasing:344443-0907 (907 g) | Anti-seize | Loctite | Loctite 8014 |
| 344469-7277 (400 g) | Grease | Fuchs | Cassida Grease HDS 2 |
| 344477-0000Reference for purchasing:344477-0075 (75 ml)344477-1000 (1 l) | Silicon Grease | Loctite | Loctite LB 8104 |
| 1607000-0000Reference for purchasing:1607000-0020 (20 l) | Hydraulic Oil | Tetra Pak | Hydraulic H1-0500, PAO HLP32 |
| 1607001-0000Reference for purchasing:1607001-0020 (20 l) | Hydraulic Oil | Tetra Pak | Hydraulic H1-0520, PAO HLP46 |
| 1607010-0000Reference for purchasing:1607010-0005 (5 l)1607010-0020 (20 l) | Central Lubrication Oil | Tetra Pak | Lubricant H1-0500, PAO v320 |
| 1607031-0000Reference for purchasing:1607031-0100 (95 g)1607031-0001 (1 kg) | Lubricating Grease | Tetra Pak | Grease H1-0520, PAO Nlgi 2 |
| Lubricants Valid until machine 63202/20066, without UK Food Grade Lubricants TT3, Kit No 3355833-0100For machines with food grade lubricants, see the table Reference. |
| TP Part No.(used when ordering from TetraPak) | Lubricant Type | Example |
| Supplier | Product Designation |
| 90458-2734 | Gearbox Oil | Mobil | Mobil SHC 630 |
| Mereta | Mereta 220 |
| 90606-4796 (380 g) | Pneumatic Grease | Shell | AeroShell Grease 22 |
| 344407-0000Reference for purchasing:344407-0285 (45 g)344407-0591 (400 g)344407-0037 (1 kg)344407-0177 (25 kg) | Lubrication Grease | Klüber | Klübersynth UH1 14-151 |
| 344417-0000Reference for purchasing:344417-0213 (60 g)344417-0594 (500 g)344417-0046 (600 g) | Sliding Agent Anti Seize <120°C | Klüber | Klüberpaste UH1 84-201 |
| 344418-0000Reference for purchasing:344418-0319 (80 g)344418-0589 (600 g) | Sliding Agent Anti Seize >120°C | Klüber | Klüberpaste UH1 96-402 |
| 344443-0000Reference for purchasing:344443-0907 (907 g) | Anti-seize | Loctite | Loctite 8014 |
| 344469-7277 (400 g) | Grease | Fuchs | Cassida Grease HDS 2 |
| 344472-3213 (20 l) | Central Lubrication Oil | Shell | OMALA S2 GX 320, Pail |
| 344474-4603 (20 l) | Hydraulic Oil | Shell | Tellus S2 V 46, Pail |
| 344477-0000Reference for purchasing:344477-0075 (75 ml)344477-1000 (1 l) | Silicon Grease | Loctite | Loctite LB 8104 |
| 1607000-0000Reference for purchasing:1607000-0020 (20 l) | Hydraulic Oil | Tetra Pak | Hydraulic H1-0500, PAO HLP32 |
| 1607031-0000Reference for purchasing:1607031-0100 (95 g)1607031-0001 (1 kg) | Lubricating Grease | Tetra Pak | Grease H1-0520, PAO Nlgi 2 |
Chemicals for Cleaning and Disinfection
Risk of explosion.Only use Tetra Pak recommended cleaning agents when cleaning or disinfecting parts that can come into contact with hydrogen peroxide.Cleaning with non recommended cleaning agents, for example agents including alcohol, can cause explosions if they come into contact with hydrogen peroxide.
Hazardous substances.Read the manufacturer’s instructions and carefully follow the warning texts on the containers. Also see Section Hazardous Substances in the Safety Precautions chapter.Contact with chemicals can be hazardous to your health.
Hazardous substances.Do not use chlorine or iodine based cleaning agents or disinfectants when cleaning or disinfecting parts that can come into contact with hydrogen peroxide.Risk of hydrogen peroxide decomposition.
Comparable qualities from other suppliers may be selected in compliance with the technical requirements listed in the table.All cleaning agents/disinfectants must comply with local legal requirements.The supplier recommendations for concentration and temperature should be followed. When dosing the products automatically, their concentrations should be checked.| Operation | Type | Pure chemicals | Formulated Products ***** |
| Chemical | In-use solution w/w | In-use temperature | Ecolab **** | Diversey **** | In-use solution | In-use Temperature |
| Cleaning in Place (CIP) | Alkali detergent | NaOH | Target | Min/max | Target | Min/max | | Cipton VC 11** | "In accordance with suppliers re- commendation | Target | Min/max |
| 1.3% | min1% | 80°C (176°F) | min75°C (167°F) | 80°C (176°F) | min75°C(167°F) |
| Mip CA | | | | | |
| max1.5% | max85°C (185°F) | max85°C (185°F) | | | | | |
| Acid detergent | HNO3 | 0.8% | min0.6% | 60°C (140°F) | min 60°C (140 °F) | P3-horolith L31 | Pascal VA 05 | 60°C (140°F) | min 60°C (140°F) |
| H3PO4 | P3-horolith CIP | Aluwash VA 03 | | | |
| H3PO4+HNO3 | max1% | max65°C (149 °F) | P3-horolith FL | Super Dilac VA 04 | max65°C (149°F) |
| P3-horolith V | | | | | | |
| ***) Preferred by Tetra Pak | | | | | | | | | |
| ****) Only if detergents do not foam | | | | | | | | |
| *****) One way to ensure that the concentration of NaOH, HNO3, or H3PO in the cleaning solutions do not exceed the maximum value, is to use formulated cleaning detergents. Formulated cleaning detergents contain, besides lower concentration of NaOH, HNO3, or H3PO, additives to enhance their cleaning effects. |
| Operation | Type | Pure chemicals | Formulated Products |
| Chemical | In-use solution w/w | In-use temperature | Ecolab **** | Diversey **** | In-use solution | In-use Temperature |
| Cleaning and Disinfection of the Hygiene Chamber (TTCU) | Alkali detergent | NaOH *** | 0.3% | 60°C (140°F) | | Cipton VC 11** | "0.3% alkali in accordance with procedures in IM/MM | 60°C (140°F) |
| Mip CA | | | | | |
| Acid detergent | HNO3 *** | 0.3% | P3-horolith L31 | Pascal VA 05 | 0.3% acid in accordance with procedures in IM/MM |
| | P3-horolith FL | Aluwash VA 03Super Dilac VA 04 | | |
| P3-horolith V | | | | | | | |
| Disinfectant | | 30°C (86°F) | P3-Oxonia Active | Divosan active VT5 | 1500 ppm PAA (TT/3 ASD, AW & ASCM)750 ppm (TT/3 XH&XHIC) | 30°C (86°F) |
| P3-Oxonia Active 150*** | Divosan forte VT06 *** | | | | | | |
| Manual Cleaning, wiping | Alkali solution***** | | P3-mip FPC | Fillerclean VK 12 | 2% | Ambient |
| P3-topax 12 | | 3% | | | | | |
| Manual cleaning, wiping, LFU | Alcoholic solution | Isopropanol | 70% | Ambient | Spitaderm | Alcosan VT 10 | Pure |
| Ethanol | 70% | Alcodes | | | | | |
| Manual cleaning, removal of hydraulic oil | | | P3-Mip FPC 2% | | |
| Topaz LD1 2% | | | | | | | |
| Manual Disinfection, spraying | Alcoholic solution | Isopropanol | 70% | Ambient | Spitaderm | Alcosan VT 10 | Pure |
| Ethanol | 70% | Alcodes | | | |
| Hand Disinfection | Disinfectant | | Manodes | H4 | Pure |
| H34 | | | | | | |
| ***) Preferred by Tetra Pak | | | | | | | | |
| ****) Only if detergents do not foam | | | | | | | |
| *****) Never use alkali solution on the LFU | | | | | | | | |
ASU
| Description | Object |
| RulerTP No. 1147543-0000Quantity: 1Used for: Settings |  |
| Template OvenTP No. 2523707-0000Quantity: 1Used for: Settings |  |
| Plastic Film TP No. 1355671-0000Quantity: -Used for: Settings |  |
| TemplateTP No. 2712575-0001 (BASE)TP No. 2712575-0002 (MIDI)TP No. 2712575-0003 (MINI)TP No. 2712575-0004 (MICRO)Used for: Settings of the bending rollers. |  |
| Support RollerTP No. 3383226-0000 (MINI)Quantity: 1Used for: Setting of female crease roller |  |
| TemplateTP No. 3431312-0000Quantity: 1Used for: Setting of Strip Applicator Version 2 |  |
Carton Section
| Description | Object |
| Template Cutting Unit2950400-0101Quantity: 1Used for: Settings of paper feed. |  |
| Tool erector fingers TP No. 1185397-0101Quantity: 1Used for: Mounting of springs in erector fingers. |  |
| Template Centering Sword TP No. 1480292-0000 (BASE, MIDI, MINI)TP No. 2605313-0000 (MICRO)Quantity: 2Used for: Settings of sliderail (sword) position to sleeve forming rollers. |  |
| Sleeve Tester TP No. 1469631-0200Quantity: 1Used for: Testing of sleeve size. |  |
| Sleeve size meter (Midi)TP No. 3446200-0100Quantity: 1Used for: Testing of sleeve size(Opened sleeve). |  |
| Sleeve size meter (Mini)TP No. 3446224-0100Quantity: 1Used for: Testing of sleeve size(Opened sleeve). |  |
| Grease Gun TP No. 950926Quantity: 1 |   |
| Template LS Rollers TP No. 977855-0301Quantity: 1Used for: Settings to get:1/ Sleeve forming squeezer wheels in parallel.2/ To set distance between sleeve forming squeezer wheels. |  |
| Tool Zeroing Rod TP No. 988851-0000Quantity: 1Used for: Zero-setting for cam module erector. |  |
| Tool Zeroing Rod TP No. 977709-0000Quantity: 1Used for: Zero-setting for cam module cut and fold. |  |
| Tool Template Folder TP No. 1185776-0101 (BASE/BASE)TP No. 1185776-0102 (MIDI/MIDI)TP No. 1185776-0103 (MINI/MINI)TP No. 1185776-0104 (MICRO/MICRO)Quantity: 1Used for: Setting of folding plates and folding bars relative conveyor. |  |
| Template Forming TubesTP No. 977990-0301 (BASE)TP No. 977990-0302 (MIDI)TP No. 977990-0303 (MINI)TP No. 977990-0304 (MICRO)Quantity: 1 setUsed for: Setting of forming tubes vs. mandrels. |  |
| Setting Template (MiniV)TP No. 3442653-0000Quantity: 1Used for: Setting of forming tubes vs. mandrels. |  |
| Template Sleeve Former TP No. 989757-0000 (BASE)Quantity: 1Used for: Settings of outer sleeve forming roller row. |  |
| Template Sleeve Rollers TP No. 1480203-0000 (BASE)TP No. 1502215-0000 (MIDI)TP No. 1116898-0201 (MINI)TP No. 2605316-0000 (MICRO)Quantity: 2Used for: Setting of distance between sleeve former rows. |  |
| Template Folder TP No. 1477274-0000 (BASE)TP No. 1502771-0000 (MIDI)TP No. 1295843-0000 (MINI/MICRO).Quantity: 1Used for: Settings of folding plates distance to folding bar. |  |
| Template Sleeve Former TP No. 1521236-0000 (MIDI)Quantity: 1Used for: Settings of outer sleeve forming roller row. |  |
| Template Sleeve Rollers TP No. 1127991-0101 (MINI)TP No. 1127991-0102 (MICRO)Quantity: 1Used for: Settings of outer sleeve forming roller row. |  |
| Dynamometer TP No. 74767-0102Quantity: 1Used for: Check belt tension. |  |
| Belt Tension MeterTP No. 90459-2181Quantity: 1Used for: Check the belt tension. |  |
| Template LS-Owen TP No. 1477310-0000 (BASE)TP No. 1477312-0000 (BASE)TP No. 1502290-0000 (MIDI)TP No. 1521728-0000 (MINI)TP No. 2605291-0000 (MICRO)Quantity: 1Used for: Setting the gap between the cooling bodies. |  |
| Measuring InstrumentTP No. 1567930-0101Quantity: 1Used for: Aligning the pusher against the forming plates. |  |
| Template Pre-FolderTP No. 2758258-0000Quantity: 1Used for: Setting of the angel piece for the pre-folder. |  |
| Template Pre-FolderTP No. 2758259-0000Quantity: 1Used for: Setting of the pre-folder height. |  |
| Template Uni CutterTP No. 2968239-0000 (BASE GOLDECK, ORINOCO)TP No. 2979587-0000 (MIDI HURON)Quantity: 1Used for: Setting the cutting profiles. |  |
LFU
| Description | Object |
| Template vertical guideTP No. 2787510-0100Quantity: 1Used for: Used during Basic Aligning. |  |
| Ruler TP No. 2678694-0100 which contains_- Ruler 2646208Quantity: 4, 1000 mmUsed for: Alignment of the LFU G2.- Ruler bracket 1573173Quantity: 8Used for: Alignment of the LFU G2.- Ruler distance bracket 1573175Quantity: 2Used for: Alignment of the LFU G2. |  |
| Assembly tool TP No. 1551475Quantity: 1Used for: Lift out the transfer unit. |  |
| Puller TP No. 1573180Quantity: 1Used for: Removing the link arm. |  |
| Puller TP No. 1573181Quantity: 1Used for: Removing the link arm. |  |
| Belt Tension MeterTP No. 90459-2181Quantity: 1Used for: Check the belt tension. |  |
| PullerTP No. 1573950-0000Quantity: 1Used for: Assemble bearings in the belt shaft. |  |
| Scraper TP No. 1573970Quantity: 1Used for: Remove plastic from the hot channel. |  |
| Hydraulic service hose TP No. 2646205Quantity: 1Used for: Extend the hydraulic hose to the LFU G2. |  |
| Hydraulic service hose TP No. 2646206Quantity: 1Used for: Extend the hydraulic hose to the LFU G2. |  |
| Removal Tool TP No. 1572245Quantity: 1Used for: Used to remove screws to the internal tool. |  |
| Syringe TP No. 90459-3578Quantity: 1Used for: Fill up the planetary gear with oil. |  |
| Pre-Loading equipment:TP No. C-996373-010V which contains:- Filler 90243-0429- Adapter (article no. depends on market)Quantity: 1Used for: Pre-loading accumulator. |  |
| Pressure GaugeTP No. C-1116814-0101 which includes:- Pressure Gauge 90043-0075- Measuring Hose 90201-0426Quantity: 1Used for: Check hydraulic pressure in LFU. |  |
| Pressure GaugeTP No. C-2677917-0101 which includes:- Pressure Gauge 90243-0429- Measuring Hose 90201-0426Quantity: 1Used for: Check hydraulic pressure in LFU. |  |
| Opening force tester TP No. 2768297-0100Quantity: 1Used for: Check opening forces. |  |
| Puller inner toolTP No. 591976 (BASE)Quantity: 1Used for: Removing of inner tool. |  |
| Puller inner toolTP No. 1298604 (MIDI, MINI & MICRO)Quantity: 1Used for: Removing of inner tool. |  |
| Sampling ValveTP No. 1590255Quantity: 1Used for: Take oil sample from hydraulic unit. |  |
| Plug ToolTP No. 2742034-0000Quantity: 1Used for: Assembling cover plug for internal tool´s fitting to mandrel. |  |
| Deep GaugeTP No. 2760316Quantity: 1Used for: Basic aligning of the LFU. |  |
| Deep GaugeTP No. 3424768Quantity: 1Used for: Basic aligning of the LFU. |  |
| Measuring toolTP No. 2787511-0100Quantity: 1Used for: During Basic Set for measuring the clearance between the mandrel wheel and the vertical system. |  |
| StopTP No. 2799379Quantity: 1Used for: During Basic Set stop the holders to fall down. |  |
| Locking LoopTP No. 3674453-0000Quantity: 1Used for: Keeping the scissors in locked position during service of the LFU. |  |
| Cleaning Wire BrushTP No. 2888712Quantity: 1Used for: Cleaning the transfer unit. |  |
| Drive mandrelTP No. 2888711Quantity: 1Used for: Removing the transfer unit screw. |  |
| Drive mandrelTP No. 2864304Quantity: 1Used for: Change the transfer unit bearing house. |  |
| Drive MandrelTP No. 2888710Quantity: 1Used for: Changing bushings on the vertical guide steering. |  |
| SleeveTP No. 2888709Quantity: 1Used for: Installing scraper rings and seals. |  |
| KeyTP No. 2838501-0000Quantity: 1Used for: Non-return valve 90459-2852. |  |
| KeyTP No. 2956635-0000Quantity: 1Used for: Non-return valve 90201-0134. |  |
| KeyTP No. 2838503-0000Quantity: 1Used for: Non-return valve 90459-2879. |  |
| KeyTP No. 3266349-0000Quantity: 1Used for: Check-valve 90459-2874. |  |
| KeyTP No. 2838500-0000Quantity: 1Used for: Check-valve 90459-2874. |  |
| KeyTP No. 2848804-0000Quantity: 1Used for: Non-return valve 90459-2877. |  |
| HookTP No. 2787509-0000Quantity: 1Used for: Removing plastic residue. |  |
| RailTP No. 915399-0200Quantity: 1Used for: Removing the LFU from the machine. |  |
| Carriage for LFU RailsTP No. 3416603-0100Quantity: 2Used for: Transporting LFU rails. |  |
| Contact paperTP No. 1573457-0000Quantity: 1Used for: Check the contact pressure between the hotchannel and the external tools. |  |
| Drive mandrelTP No. 2811656-0000Quantity: 1Used for: Changing the bushings in the hanger. |  |
| Key Reference CylinderTP No: 3544947Quantity: 1Used for: Loosing and tightening Reference Cylinders |  |
| Template, Mini Eifel C38TP No. 3684339-0000Quantity: 2Used for: Check and Set of Initial CavityTemplate, Mini Eifel C38 V2TP No. 3750645-0000Quantity: 2Used for: Check and Set of Initial Cavity |  |
| Template, Midi Eifel C38TP No. 3685644-0000Quantity: 2Used for: Check and Set of Initial CavityTemplate, Midi Eifel C38 V2TP No. 3727285-0000Quantity: 2Used for: Check and Set of Initial Cavity |  |
| Template, Mini Nallo C38TP No. 3700965-0000Quantity: 2Used for: Check and Set of Initial CavityTemplate, Mini Nallo C38 V2TP No. 3748317-0000Quantity: 2Used for: Check and Set of Initial Cavity |  |
| Template, Base Eifel C38TP No. 3725715-0000Quantity: 2Used for: Check and Set of Initial CavityTemplate, Base Eifel C38 V2TP No. 3744355-0000Quantity: 2Used for: Check and Set of Initial Cavity |  |
Cap Application Unit
| Description | Object |
| Position Template (assembly) (1)TP No. 2844893-0200Quantity: 1 for each bottom format in the machine. Position Template (2)TP No. 2989790-0000 (Screw Cap O38)TP No. 3342748-0000 (Screw Cap C38)TP No. 3738867-0000 (Screw Cap C38 V2)Quantity: 2 Position Template (3)(Forming Tube Template)TP No. 2844892-0000 (Base)TP No. 2875379-0000 (Midi)TP No. 2931921-0000 (Mini STD)TP No. 3440368-0000 (Mini V)Quantity: 2 for each bottom format in the machine. Used for: Varying settings. | 1Position Template (assembly)2Position Template3Position Template |
| Position templateTP No. 3021657-0000 (Base)TP No. 3021658-0000 (Midi)TP No. 3017554-0000 (Mini)TP No. 3531804-0000 (Midi AW)Quantity: 2 for each bottom format in the machine. Used for: Setting the CAU stripper. Used together with the Position Templates (3), the Forming Tube Templates. | 1Position template (Mini)2Position template (Midi)3Position template (Base)4Position template (Midi AW) |
| Position templateTP No. 2984195-0100Quantity: 1Note: End piece is unique depending on bottom format. Used for: To align the forming tubes with the cassettes in the package section. Used together with the Position Templates (3), the Forming Tube Templates. |  |
| ShaftTP No. 3389343-0000 (Base)TP No. 3389344-0000 (Midi)TP No. 3389345-0000 (Mini)TP No. 3750183-0000 (Base C38 V2)TP No. 3750184-0000 (Midi C38 V2)TP No. 3750185-0000 (Mini C38 V2)Quantity: 2 for each format. Used for: Setting the capping position. |  |
| Setting TemplateTP No. 2901501-0000Quantity: 1 Used for: Adjusting the height of capper unit during settings. |  |
| RodTP No. 2844915-0000Quantity: 1 Used for: Setting of zero position for magazine unit. |  |
| Position TemplateTP No. 3017556-0000TP No. 3721168-0000 (Screw Cap C38 V2)Quantity: 1 Used for: Aligning the mandrels with the cutters. |  |
| Setting TemplateTP No. 3061051-0000 (Screw Cap O38)Quantity: 2 Used for: Aligning the pushers and the tubes in the cap transfer with the cap holders in the capper unit. |  |
| Setting TemplateTP No. 3568597-0000 (Screw Cap C38)TP No. 3729169-0000 (Screw Cap C38 V2)Quantity: 2 Used for: Aligning the pushers and the tubes in the cap transfer with the cap holders in the capper unit. |  |
| Cap Holders Group (1)TP No. 2899088-0000Quantity: 1 Cap Holder (2)TP No. 2899087-0000 (Screw Cap O38)TP No. 3361546-0000 (Screw Cap C38)Quantity: 1 Used for: Package checks | 1Cap Holders Group2Cap Holder |
| Valve GuideTP No. 90458-2888Quantity: 1 Used for: Locking the valves in the pneumatic panel. |  |
Package Section
| Description | Object |
| UV MeterTP No. 1469760-0301Quantity: 1Used for: Check intensity of UV-lamp. |  |
| UV MeterValid for: UK REPL UV Meter 90459-3591 TT3, 3726539-0100TP No. 1469760-0302Quantity: 1Used for: Check intensity of UV-lamp. |  |
| Instrument HousingTP No. 1590181-0000 (MiniV)Quantity: 1Used for: |  |
| Template BSTP No. 2633209-0101Quantity: 1Used for: Setting of bottom sealing. |  |
| Assembly tool BSTP No. 2633197-0101Quantity: 1Used for: Assembling of bottom sealing. |  |
| Template FF/ovenTP No. 1116653 (Base)TP No. 1502242 (Midi)TP No. 1309694 (Mini)TP No. 2651150 (Micro)Quantity: 1Used for: Setting of flap heater. |  |
| Template FFTP No. 1116652 (Base)TP No. 1502244 (Midi)TP No. 1477039 (Mini)TP No. 2651151 (Micro)Quantity: 1Used for: Setting of package steering. |  |
| TemplateTP no. 3404250-0100 (Mini)Quantity: 1Used for: Setting of bottom Squeezer |  |
| Setting TemplateTP No. 3440370-0000 (MiniV)Quantity: 1Used for: Setting of package steering. |  |
| Setting TemplateTP No. 3440379-0000 (MiniV)Quantity: 2Used for: Setting of flap heater. |  |
| TemplateTP No. 3457182-0100 (MiniV)Quantity: 1Used for: Setting of bottom Squeezer. |  |
| Excenter handleTP No. 2681250Quantity: 1Used for: Bottom sealing cassette lift. |  |
| Template bottom TP No. 1506569 (Base/Base)TP No. 1590562 (Midi/Midi)TP No. 1521727 (Mini/Mini)TP No. 2651657 (Micro/Micro)Quantity: 2Used for: Setting of flap heater. |  |
| Template railTP No. 2734160Quantity: 1Used for: Setting of guide rails. |  |
| Template railTP No. 2758018Quantity: 1Used for: Setting of guide rails. |  |
| Template guide railTP No. 1481936Quantity: 2Used for: Setting of guide rails. |  |
| Template conveyor TP No. 915329-0101Quantity: 1Used for: Setting of guide rails. |  |
| Squeezer templateTP No. 1572464 (Base/Base)TP No. 1572463 (Midi/Midi)TP No. 1572462 (Mini/Mini)TP No. 2651149 (Micro/Micro)Quantity: 1Used for: Setting of flap guide. |  |
| Hook spanner TP No. 90600-0807Quantity: 1Used for: Setting of sonotrode unit. |  |
| Template cassette TP No. 1025194-0201Quantity: 1Used for: Check and straightening of cassettes. |  |
| Guiding arborTP No. 3440371-0000 (MiniV)Quantity: 1Used for: |  |
| YokeTP No. 1025049-0101Quantity: 1Used for: Removal of bottom sealing unit. |  |
| Tackle block TP No. 90039-19Quantity: 1Used for: Removal of bottom sealing unit. |  |
| TemplateTP No. 2734157-0101Quantity: 1Used for: Current limit setting for volume change DC-motors |  |
| Rail TP No. 915399-0201Quantity: 1Used for: Removal of bottom sealing unit. |  |
| Rail TP No. 3389677-0100Quantity: 1Used for: Removal of bottom sealing unit. |  |
| Template Cassette DistanceTP No. 2704220 (Base)TP No. 2704222 (Midi)TP No. 2704223 (Mini)TP No. 2704224 (Micro)Quantity: 1Used for: Check of cassettes by straightening tool. |  |
| Template Cassette DistanceTP No. 2710959Quantity: 1Used for: Check of cassettes by straightening tool. |  |
| Tool for LKM MR-200STP No. 90458-0248Quantity: 1Used for: Removing and installing the stationary seal ring. |  |
Filling Section
| Description | Object |
| Vacuum generatorTP No. 1304364-0101Quantity: 1Used for: Settings |  |
| PinTP No. 2886550-0000 (Base, Midi, Mini)Quantity: 1Used for: Check of piston centring in pump cylinder. |  |
| Assembly tool, diaphragmTP No. 1094870-0000 (Micro)Quantity: 1Used for: Folding tool for diaphragms to the piston pump. |  |
| Assembly tool, valve cone TP No. 2697051-0000 (Base, Midi, Mini - not ADY)Quantity: 1Used for: Mounting tool for universal product valves (UPV). |  |
| Assembly tool, valve coneTP No. 1339397-0000 (Micro)Quantity: 1Used for: Mounting tool for universal product valves (UPV). |  |
| Assembly tool, valve coneTP No 2789096-0000 (ADY)Quantity: 1Used for: Mounting tool for universal product valves (UPV). |  |
| Tightening toolTP No. 90600-0646Quantity: 1Used for: Mounting tool for diaphragm valves. |  |
| Hook spanner 18 mmTP No. 90458-1544Quantity: 1Used for: Mounting tool for diaphragm valves. |  |
| Hook spanner 25 mmTP No. 90458-1545Quantity: 1Used for: Mounting tool for diaphragm valves. |  |
| Hook spanner 38 mmTP No. 90458-1546Quantity: 1Used for: Mounting tool for diaphragm valves. |  |
| Hook spanner 51 mmTP No. 90458-1547Quantity: 1Used for: Mounting tool for diaphragm valves |  |
| TubeTP No. 2704204-0000Quantity: 1Used for: Leakage check of universal product valves (UPV). |  |
| Lifting toolTP No. 90606-8294Quantity: 1Used for: Removing parts of the agitator in the filling tank. |  |
| Female Bearing Replacement KitTP No. 90606-8299Quantity: 1Included parts: Pliers, TP No. 90607-0341, Heat Sink, TP No. 90607-0343, Heat Protection, TP No. 906070344Used for: Removing parts of the agitator in the filling tank. |  |
| Service toolTP No. 3414407-0000Quantity: 1Used for: Removing and installing bushing and scraper ring. |  |
| Service toolTP No. 3414409-0000Quantity: 1Used for: Removing and installing bushing and scraper ring. |  |
| Service toolTP No. 3414410-0000Quantity: 1Used for: Removing and installing bushing and scraper ring. |  |
| Servo cableTP No. 90603-8653Quantity: 1Used for: Set settings in servo motor. |  |
| TemplateTP No. 3449340-0000Quantity: 1Used for: Move servo motor shaft. |  |
| CoverTP No. 3409260-0000Quantity: 1Used for: Protecting filling pipe edges. |  |
| NozzleTP No. 3258460-0100Quantity: 1Used for: Testing with water after maintenance. |  |
Overview

The illustration shows the USA/Canada variant of the machine.
Covers and Doors
Door guards are placed symmetrically on both sides of the machine.For more information about the electrical safety system, see Chapter Safety System.Safety Switches - Check
| Equipment Status | Program Step |
See Safety Precautions for locations of the safeguards.Note: On some machines (Brazil) the doors must be closed before the alarm can be acknowledged on the TPOP . The yellow warning lamp will a fixed light.- Step up the machine to Pre-heating.
- Open a door and check that the TPOP ladder stops flashing.
- When the door is open, confirm that the corresponding door symbol on the TPOP appears and the yellow warning lamp is flashing. If not, replace the door safety switch and set it according to procedure Safety Switch - Set and perform a new check.
- Acknowledge the alarm on the TPOP,
- the yellow warning lamp shows a fixed light.
- Close the door,
- the corresponding door symbol on the TPOP and the yellow warning lamp goes out.
- Repeat the item Reference to Reference on all doors.
For a more accurate test perform the TT/3 2000 safety system check as follows. Perform this test every time the safety system have been rebuilt, reconnected or if a component in the safety system have been replaced by another.
Check Service Switch Function
- Activate all Safety Relay (Service Switch in OFF position, left)
- Step the machine down to AIR OFF.
| Perform following: | Check that: | Sign |
| Turn the Service Switch A01S0187 to ON position (right) | Only F03K0007 and F03K0013 are activated | |
| Turn the Service Switch A01S0187 till OFF position (left) | All Safety Relays are activated | |
The Service Switch must be switched Off (left) to continue the Safety System Check Procedure.
Check Door Guard Function
Check the Safety Relay Shutdown, the alarms on the TPOP, and the prevention of step up possibility.- Step the machine down to step zero.
- Make sure that the Hatches, on both sides, between Carton and Package Section are closed. If a Hatch is open, both Carton Section and Package Section Safety Relays will shut down when opening a door.
- Acknowledge any alarm on the TPOP and step up the machine.
ASU, Carton Section, and CAU Doors
Pluto modules in El Cab| Pluto 3 | Pluto 4 |
| F03K0014 | F03K0016 |
Safety Relays in El Cab. (The non-shaded Relays will be tested).| F03K0007 | F03K0008 | F03K0010 | F03K0011 | F03K0012 | F03K0013 |
| Em Stop XL12 | CS XL21 | CS XL22 | PS XL31 | PS XL32 | Hydr Mot |
NR12| F03K1253 | F03K2253 | F03K0255 | F03K0255 |
| UV lamp S1 | UV lamp S2 | Hatch/CS Air | Em Stop Main Air |
| Ref. Des: | Door Guard/Safety Relays | Perform and check | Sign |
| F03B1202F03K0008 F03K0010 F03K0013NR12F03K0255 | ASU1 SA-Oven doorCS XL21CS XL22CS Hydr. MotorNR12Hatch/CS | 1. Check that the Safety Relays are activated 2. Open and close the door 3. Check that the Safety Relays have shut down4. Try to step up both sides. It should not be possible!5. Check that actual door alarm is shown on the TPOP.6. Acknowledge the alarm from the TPOP7. After 6 sec the Safety Relays activates8. Check that it's possible to step up both sides9. Check that both sides are in step zero | 1.____2.____3.____4.____5.____6.____7.____8.____9.____ |
| F03B2202F03K0008F03K0010F03K0013NR12F03K0255 | ASU2 SA-Oven DoorCS XL21 CS XL22 CS Hydr. MotorNR12Hatch/CS | 1. Open and close the door2. Check that the Safety Relays have shut down3. Try to step up both sides. It should not be possible!4. Check that actual door alarm is shown on the TPOP.5. Acknowledge the alarm from the TPOP6. After 6 sec the Safety Relays activates7. Check that it's possible to step up both sides8. Check that both sides are in step zero | 1.____2.____3.____4.____5.____6.____7.____8.____ |
| F03B1213F03K0008 F03K0010 F03K0013NR12F03K0255 | CS1 LFU Mandrel Wheel Door CS XL21CS XL22 CS Hydr. MotorNR12Hatch/CS | 1. Open and close the door 2. Check that the Safety Relays have shut down3. Try to step up both sides. It should not be possible!4. Check that actual door alarm is shown on the TPOP.5. Acknowledge the alarm from the TPOP6. After 6 sec the Safety Relays activates7. Check that it's possible to step up both sides8. Check that both sides are in step zero | 1.____2.____3.____4.____5.____6.____7.____8.____ |
| F03B1214F03K0008 F03K0010 F03K0013NR12F03K0255 | CS1 Sleeve Erector Door CS XL21 CS XL22 CS Hydr. MotorNR12Hatch/CS | 1. Open both doors.2. Close the locking door and leave the actual door open3. Acknowledge the alarms on the TPOP.4. Check that actual door alarm is shown on the TPOP.5. Check that the Safety Relays shut down6. Try to step up both sides. It should not be possible!7. Close both doors8. Acknowledge the alarm so it disappears on the TPOP9. After 6 sec the Safety Exp Relays activates10. Check that it is possible to step up both sides11. Check that both sides are in step zero | 1.____2.____3.____4.____5.____6.____7.____8.____9.____10.___11.___ |
| F03B1215F03K0008 F03K0010 F03K0013NR12F03K0255 | CS1 TPOP Door CS XL21 CS XL22 CS Hydr. MotorNR12Hatch/CS | 1. Open both doors. 2. Close the locking door and leave the actual door open 3. Acknowledge the alarms on the TPOP.4. Check that actual door alarm is shown on the TPOP.5. Check that the Safety Relays shut down6. Try to step up both sides. It should not be possible!7. Close both doors8. Acknowledge the alarm so it disappears on the TPOP9. After 6 sec the Safety Exp Relays activates10. Check that it is possible to step up both sides11. Check that both sides are in step zero | 1.____2.____3.____4.____5.____6.____7.____8.____9.____10.___11.___ |
| F03B1216F03K0008 F03K0010 F03K0013NR12F03K0255 | CS1 Cutting Door CS XL21 CS XL22 CS Hydr. MotorNR12Hatch/CS | 1. Open and close the door2. Check that the Safety Relays have shut down3. Try to step up both sides. It should not be possible!4. Check that actual door alarm is shown on the TPOP.5. Acknowledge the alarm from the TPOP6. After 6 sec the Safety Relays activates7. Check that it's possible to step up both sides 8. Check that both sides are in step zero | 1.____2.____3.____4.____5.____6.____7.____8.____ |
| F03B1201F03K0008 F03K0010 F03K0013NR12F03K0255 | CAU1 Magazine Door (If CAU option) CS XL21 CS XL22 CS Hydr. MotorNR12Hatch/CS | 1. Open and close the door2. Check that the Safety Relays have shut down3. Try to step up both sides. It should not be possible!4. Check that actual door alarm is shown on the TPOP.5. Acknowledge the alarm from the TPOP6. After 6 sec the Safety Relays activates7. Check that it's possible to step up both sides8. Check that both sides are in step zero | 1.____2.____3.____4.____5.____6.____7.____8.____ |
| F03B1209F03K0008 F03K0010 F03K0013NR12F03K0255 | CS1 LFU Tools DoorCS XL21 CS XL22 CS Hydr. MotorNR12Hatch/CS | 1. Open and close the door 2. Check that the Safety Relays have shut down3. Try to step up both sides. It should not be possible!4. Check that actual door alarm is shown on the TPOP.5. Acknowledge the alarm from the TPOP6. After 6 sec the Safety Relays activates7. Check that it's possible to step up both sides8. Check that both sides are in step zero | 1.____2.____3.____4.____5.____6.____7.____8.____ |
| F03B1210F03K0008 F03K0010 F03K0013NR12F03K0255 | CS1 LFU Extruder Door CS XL21 CS XL22 CS Hydr. MotorNR12Hatch/CS | 1. Open both doors.2. Close the locking door and leave the actual door open 3. Acknowledge the alarms on the TPOP.4. Check that actual door alarm is shown on the TPOP.5. Check that the Safety Relays shut down6. Try to step up both sides. It should not be possible!7. Close both doors8. Acknowledge the alarm so it disappears on the TPOP9. After 6 sec the Safety Exp Relays activates10. Check that it is possible to step up both sides11. Check that both sides are in step zero | 1.____2.____3.____4.____5.____6.____7.____8.____9.____10.___11.___ |
| F03B1211F03K0008 F03K0010 F03K0013NR12F03K0255 | CS1 Water Circ. DoorCS XL21 CS XL22 CS Hydr. MotorNR12Hatch/CS | 1. Open both doors.2. Close the locking door and leave the actual door open3. Acknowledge the alarms on the TPOP.4. Check that actual door alarm is shown on the TPOP.5. Check that the Safety Relays shut down6. Try to step up both sides. It should not be possible!7. Close both doors8. Acknowledge the alarm so it disappears on the TPOP9. After 6 sec the Safety Exp Relays activates10. Check that it is possible to step up both sides11. Check that both sides are in step zero | 1.____2.____3.____4.____5.____6.____7.____8.____9.____10.___11.___ |
| F03B1212F03K0008 F03K0010 F03K0013NR12F03K0255 | CS1 Perox. Pump Door CS XL21 CS XL22 CS Hydr. MotorNR12Hatch/CS | 1. Open and close the door 2. Check that the Safety Relays have shut down3. Try to step up both sides. It should not be possible!4. Check that actual door alarm is shown on the TPOP.5. Acknowledge the alarm from the TPOP6. After 6 sec the Safety Relays activates7. Check that it's possible to step up both sides8. Check that both sides are in step zero | 1.____2.____3.____4.____5.____6.____7.____8.____ |
| F03B2213F03K0008 F03K0010 F03K0013NR12F03K0255 | CS2 LFU Mandrel Wheel Door CS XL21 CS XL22 CS Hydr. MotorNR12Hatch/CS | 1. Open both doors.2. Close the locking door and leave the actual door open3. Acknowledge the alarms on the TPOP.4. Check that actual door alarm is shown on the TPOP.5. Check that the Safety Relays shut down6. Try to step up both sides. It should not be possible!7. Close both doors8. Acknowledge the alarm so it disappears on the TPOP9. After 6 sec the Safety Exp Relays activates10. Check that it is possible to step up both sides11. Check that both sides are in step zero | 1.____2.____3.____4.____5.____6.____7.____8.____9.____10.___11.___ |
| F03B2214F03K0008 F03K0010 F03K0013NR12F03K0255 | CS2 LFU Sleeve Erector Door CS XL21 CS XL22 CS Hydr. MotorNR12Hatch/CS | 1. Open and close the door2. Check that the Safety Relays have shut down3. Try to step up both sides. It should not be possible!4. Check that actual door alarm is shown on the TPOP.5. Acknowledge the alarm from the TPOP6. After 6 sec the Safety Relays activates7. Check that it's possible to step up both sides8. Check that both sides are in step zero | 1.____2.____3.____4.____5.____6.____7.____8.____ |
| F03B2215F03K0008 F03K0010 F03K0013NR12F03K0255 | CS2 TPOP Door CS XL21 CS XL22 CS Hydr. MotorNR12Hatch/CS | 1. Open both doors. 2. Close the locking door and leave the actual door open 3. Acknowledge the alarms on the TPOP.4. Check that actual door alarm is shown on the TPOP.5. Check that the Safety Relays shut down6. Try to step up both sides. It should not be possible!7. Close both doors8. Acknowledge the alarm so it disappears on the TPOP9. After 6 sec the Safety Exp Relays activates10. Check that it is possible to step up both sides11. Check that both sides are in step zero | 1.____2.____3.____4.____5.____6.____7.____8.____9.____10.___11.___ |
| F03B2216F03K0008 F03K0010 F03K0013NR12F03K0255 | CS2 Cutting Door CS XL21CS XL22 CS Hydr. MotorNR12Hatch/CS | 1. Open and close the door 2. Check that the Safety Relays have shut down3. Try to step up both sides. It should not be possible!4. Check that actual door alarm is shown on the TPOP.5. Acknowledge the alarm from the TPOP6. After 6 sec the Safety Relays activates7. Check that it's possible to step up both sides8. Check that both sides are in step zero | 1.____2.____3.____4.____5.____6.____7.____8.____ |
| F03B2201F03K0008 F03K0010 F03K0013NR12F03K0255 | CAU2 Magazine Door (If CAU option) CS XL21 CS XL22 CS Hydr. MotorNR12Hatch/CS | 1. Open and close the door 2. Check that the Safety Relays have shut down3. Try to step up both sides. It should not be possible! 4. Check that actual door alarm is shown on the TPOP.5. Acknowledge the alarm from the TPOP6. After 6 sec the Safety Relays activates7. Check that it's possible to step up both sides8. Check that both sides are in step zero | 1.____2.____3.____4.____5.____6.____7.____8.____ |
| F03B2209F03K0008 F03K0010 F03K0013NR12F03K0255 | CS2 LFU Tools DoorCS XL21 CS XL22 CS Hydr. MotorNR12Hatch/CS | 1. Open both doors. 2. Close the locking door and leave the actual door open3. Acknowledge the alarms on the TPOP.4. Check that actual door alarm is shown on the TPOP.5. Check that the Safety Relays shut down6. Try to step up both sides. It should not be possible!7. Close both doors8. Acknowledge the alarm so it disappears on the TPOP9. After 6 sec the Safety Exp Relays activates10. Check that it is possible to step up both sides11. Check that both sides are in step zero | 1.____2.____3.____4.____5.____6.____7.____8.____9.____10.___11.___ |
| F03B2210F03K0008 F03K0010 F03K0013NR12F03K0255 | CS2 LFU Extruder Door CS XL21 CS XL22 CS Hydr. MotorNR12Hatch/CS | 1. Open and close the door2. Check that the Safety Relays have shut down3. Try to step up both sides. It should not be possible!4. Check that actual door alarm is shown on the TPOP.5. Acknowledge the alarm from the TPOP6. After 6 sec the Safety Relays activates7. Check that it's possible to step up both sides8. Check that both sides are in step zero | 1.____2.____3.____4.____5.____6.____7.____8.____ |
| F03B2211F03K0008 F03K0010 F03K0013NR12F03K0255 | CS2 Hydraulic Pump Door CS XL21 CS XL22 CS Hydr. MotorNR12Hatch/CS | 1. Open both doors. 2. Close the locking door and leave the actual door open3. Acknowledge the alarms on the TPOP.4. Check that actual door alarm is shown on the TPOP.5. Check that the Safety Relays shut down6. Try to step up both sides. It should not be possible!7. Close both doors8. Acknowledge the alarm so it disappears on the TPOP9. After 6 sec the Safety Exp Relays activates10. Check that it is possible to step up both sides11. Check that both sides are in step zero | 1.____2.____3.____4.____5.____6.____7.____8.____9.____10.___11.___ |
| F03B2212F03K0008 F03K0010 F03K0013NR12F03K0255 | CS2 Hydraulic Motor Door CS XL21 CS XL22 CS Hydr. MotorNR12Hatch/CS | 1. Open and close the door 2. Check that the Safety Relays have shut down3. Try to step up both sides. It should not be possible!4. Check that actual door alarm is shown on the TPOP.5. Acknowledge the alarm from the TPOP6. After 6 sec the Safety Relays activates7. Check that it's possible to step up both sides8. Check that both sides are in step zero | 1.____2.____3.____4.____5.____6.____7.____8.____ |
Package Section Doors
Safety Relays in El Cab. (The non-shaded Relays will be tested).| F03K0007 | F03K0008 | F03K0010 | F03K0011 | F03K0012 | F03K0013 |
| Em StopXL12 | CS XL21 | CS XL22 | PS XL31 | PS XL32 | Hydr Mot |
| Ref. Des: | Door Guard/Safety Relay | Perform and check | Sign |
| F03B1206F03K0011 F03K0012 | PS1 Front Door PS XL31 PS XL32 | 1. Check that the Safety Relays are activated2. Open and close the door3. Check that the Safety Relays have shut down4. Try to step up both sides. It should not be possible!5. Check that actual door alarm is shown on the TPOP.6. Acknowledge the alarm from the TPOP7. After 6 sec the Safety Relays activates8. Check that it's possible to step up both sides9. Check that both sides are in step zero | 1.____2.____3.____4.____5.____6.____7.____8.____9.____ |
| F03B1217F03K0011 F03K0012 | PS1 Bottom Sealing Door PS XL31PS XL32 | 1. Open and close the door2. Check that the Safety Relays have shut down3. Try to step up both sides. It should not be possible!4. Check that actual door alarm is shown on the TPOP.5. Acknowledge the alarm from the TPOP6. After 6 sec the Safety Relays activates7. Check that it's possible to step up both sides8. Check that both sides are in step zero | 1.____2.____3.____4.____5.____6.____7.____8.____ |
| F03B1218F03K0011 F03K0012 | PS1 Filling Door PS XL31 PS XL32 | 1. Open and close the door2. Check that the Safety Relays have shut down3. Try to step up both sides. It should not be possible!4. Check that actual door alarm is shown on the TPOP.5. Acknowledge the alarm from the TPOP6. After 6 sec the Safety Relays activates7. Check that it's possible to step up both sides8. Check that both sides are in step zero | 1.____2.____3.____4.____5.____6.____7.____8.____ |
| F03B1207F03K0011 F03K0012 | PS1 Discharger DoorPS XL31 PS XL32 | 1. Open and close the door2. Check that the Safety Relays have shut down3. Try to step up both sides. It should not be possible!4. Check that actual door alarm is shown on the TPOP.5. Acknowledge the alarm from the TPOP6. After 6 sec the Safety Relays activates7. Check that it's possible to step up both sides8. Check that both sides are in step zero | 1.____2.____3.____4.____5.____6.____7.____8.____ |
| F03B1208F03K0011 F03K0012 | PS1 Fill Lift Door PS XL31PS XL32 | 1. Open both doors.2. Close the locking door and leave the actual door open3. Acknowledge the alarms on the TPOP.4. Check that actual door alarm is shown on the TPOP.5. Check that the Safety Relays shut down6. Try to step up both sides. It should not be possible!7. Close both doors8. Acknowledge the alarm so it disappears on the TPOP9. After 6 sec the Safety Exp Relays activates10. Check that it is possible to step up both sides11. Check that both sides are in step zero | 1.____2.____3.____4.____5.____6.____7.____8.____9.____10.___11.___ |
| F03B2206F03K0011 F03K0012 | PS2 Front Door PS XL31 PS XL32 | 1. Open and close the door2. Check that the Safety Relays have shut down3. Try to step up both sides. It should not be possible!4. Check that actual door alarm is shown on the TPOP.5. Acknowledge the alarm from the TPOP6. After 6 sec the Safety Relays activates7. Check that it's possible to step up both sides8. Check that both sides are in step zero | 1.____2.____3.____4.____5.____6.____7.____8.____ |
| F03B2217F03K0011 F03K0012 | PS2 Bottom Sealing Door PS XL31 PS XL32 | 1. Open and close the door2. Check that the Safety Relays have shut down3. Try to step up both sides. It should not be possible!4. Check that actual door alarm is shown on the TPOP.5. Acknowledge the alarm from the TPOP6. After 6 sec the Safety Relays activates7. Check that it's possible to step up both sides8. Check that both sides are in step zero | 1.____2.____3.____4.____5.____6.____7.____8.____ |
| F03B2218F03K0011 F03K0012 | PS2 Filling Door PS XL31 PS XL32 | 1. Open and close the door2. Check that the Safety Relays have shut down3. Try to step up both sides. It should not be possible!4. Check that actual door alarm is shown on the TPOP.5. Acknowledge the alarm from the TPOP6. After 6 sec the Safety Relays activates7. Check that it's possible to step up both sides8. Check that both sides are in step zero | 1.____2.____3.____4.____5.____6.____7.____8.____ |
| F03B2207F03K0011 F03K0012 | PS2 Discharger DoorPS XL31 PS XL32 | 1. Open both doors.2. Close the locking door and leave the actual door open3. Acknowledge the alarms on the TPOP.4. Check that actual door alarm is shown on the TPOP.5. Check that the Safety Relays shut down6. Try to step up both sides. It should not be possible!7. Close both doors8. Acknowledge the alarm so it disappears on the TPOP9. After 6 sec the Safety Exp Relays activates10. Check that it is possible to step up both sides11. Check that both sides are in step zero | 1.____2.____3.____4.____5.____6.____7.____8.____9.____10.___11.___ |
| F03B2208F03K0011 F03K0012 | PS2 Fill Lift Door PS XL31 PS XL32 | 1. Open and close the door2. Check that the Safety Relays have shut down3. Try to step up both sides. It should not be possible!4. Check that actual door alarm is shown on the TPOP.5. Acknowledge the alarm from the TPOP6. After 6 sec the Safety Relays activates7. Check that it's possible to step up both sides8. Check that both sides are in step zero | 1.____2.____3.____4.____5.____6.____7.____8.____ |
Check that the door guard system act as a whole machine when a hatch between Carton and Package Section is open
- Step the machine down to step zero.
- Acknowledge any alarm on the TPOP and step up the machine.Safety Relays in El Cab. (The non-shaded Relays will be tested).
| F03K0007 | F03K0008 | F03K0010 | F03K0011 | F03K0012 | F03K0013 |
| Em Stop XL12 | CS XL21 | CS XL22 | PS XL31 | PS XL32 | Hydr Mot |
| Ref. Des: | Door Guard/Safety Relays | Perform and check | Sign |
| F03K0008 F03K0010 F03K0011 F03K0012 F03K0013 | Any door on Carton Section S1 CS XL21 CS XL22 PS XL31 PS XL32 CS Hydr. Motor | 1. Put the Hatch between Carton Section and Package Section in open position on side 1 and in closed position on side 2.2. Acknowledge all alarms on the TPOP so it is possible to step up the machine.3. Check that all Safety Relays are activated4. Open and close the door5. Check that the Safety Relays for both Carton and Package Section have shut down6. Acknowledge the alarm from the TPOP7. After 6 sec the Safety Relays activates | 1.____2.____3.____4.____5.____6.____7.____ |
| F03K0008 F03K0010 F03K0011 F03K0012 F03K0013 | Any door on Package Section S1 CS XL21 CS XL22 PS XL31 PS XL32 CS Hydr. Motor | 1. Put the Hatch between Carton Section and Package Section in open position on side 1 and in closed position on side 2.2. Acknowledge all alarms on the TPOP so it is possible to step up the machine.3. Check that all Safety Relays are activated4. Open and close the door5. Check that the Safety Relays for both Carton and Package Section have shut down6. Acknowledge the alarm from the TPOP7. After 6 sec the Safety Relays activates | 1.____2.____3.____4.____5.____6.____7.____ |
| F03K0008 F03K0010 F03K0011 F03K0012 F03K0013 | Any door on Carton Section S2 CS XL21 CS XL22 PS XL31 PS XL32 CS Hydr.Motor | 1. Put the Hatch between Carton Section and Package Section in closed position on side 1 and in open position on side 2.2. Acknowledge all alarms on the TPOP so it is possible to step up the machine.3. Check that all Safety Relays are activated4. Open and close the door5. Check that the Safety Relays for both Carton and Package Section have shut down6. Acknowledge the alarm from the TPOP7. After 6 sec the Safety Relays activates | 1.____2.____3.____4.____5.____6.____7.____ |
| F03K0008 F03K0010 F03K0011 F03K0012 F03K0013 | Any door on Package Section S2 CS XL21 CS XL22 PS XL31 PS XL32 CS Hydr. Motor | 1. Put the Hatch between Carton Section and Package Section in closed position on side 1 and in open position on side 2. 2. Acknowledge all alarms on the TPOP so it is possible to step up the machine.3. Check that all Safety Relays are activated4. Open and close the door5. Check that the Safety Relays for both Carton and Package Section have shut down6. Acknowledge the alarm from the TPOP7. After 6 sec the Safety Relays activates | 1.____2.____3.____4.____5.____6.____7.____ |
Check Emergency Stop Function
Check the Safety Relay Shutdown, the alarm on TPOP and the prevention of step up possibility.- Acknowledge any alarm on the TPOP and step up the machine.Safety Relays in El Cab. (The non-shaded Relay will be tested).
| vF03K0007 | F03K0008 | F03K0010 | F03K0011 | F03K0012 | F03K0013 |
| Em Stop XL12 | CS XL21 | CS XL22 | PS XL31 | PS XL32 | Hydr Mot |
Note: When F03K0007 shuts down, all others will also shut down!NR12| F03K1253 | F03K2253 | F03K0255 | F03K0254 |
| UV lamp S1 | UV lamp S2 | Hatch/CS Air | Em Stop Main Air |
| Ref. Des: | Emergency Stops/Safety Relay | Perform and check | Sign |
| F03S0018F03K0007NR12F03K0254 | Emergency Stop Button on El Cabinet S1 Em Stop XL12NR12Em Stop Main Air | 1. Step up the machine to Air On 2. Push the Emergency Stop Button3. Check that the machine steps down in step zero4. Check that the Safety Relay shut down5. Check that Emerg. Stop alarm is shown on the TPOP.6. Try to step up both sides. It should not be possible!7. Release the Emergency Stop buttonNR12: Acknowledge the alarm on TPOP8. After 6 sec the Safety Relay activates9. Acknowledge the alarm so it disappears on the TPOP | 1.____2.____3.____4.____5.____6.____7.____8.____9.____ |
| F03S0019F03K0007NR12F03K0254 | Emergency Stop Button on El Cabinet S2 Em Stop XL12NR12Em Stop Main Air | 1. Step up the machine to Air On 2. Push the Emergency Stop Button3 Check that the machine steps down in step zero 4. Check that the Safety Relay shut down5. Check that Emerg. Stop alarm is shown on the TPOP.6. Try to step up both sides. It should not be possible!7. Release the Emergency Stop buttonNR12: Acknowledge the alarm on TPOP8. After 6 sec the Safety Relay activates9. Acknowledge the alarm so it disappears on the TPOP | 1.____2.____3.____4.____5.____6.____7.____8.____9.____ |
| F03S0205F03K0007NR12F03K0254 | Emergency Stop Button on ASUEm Stop XL12NR12Em Stop Main Air | 1. Step up the machine to Air On2. Push the Emergency Stop Button3. Check that the machine steps down in step zero4. Check that the Safety Relay shut down5. Check that Emerg. Stop alarm is shown on the TPOP.6. Try to step up both sides. It should not be possible!7. Release the Emergency Stop buttonNR12: Acknowledge the alarm on TPOP8. After 6 sec the Safety Relay activates9. Acknowledge the alarm so it disappears on the TPOP | 1.____2.____3.____4.____5.____6.____7.____8.____9.____ |
| F03S1203F03K0007NR12F03K0254 | Emergency Stop Cord S1 (PS1) Em Stop XL12NR12Em Stop Main Air | 1. Step up the machine to Air On 2. Pull the Emergency Stop Cord3. Check that the machine steps down in step zero4. Check that the Safety Relay shut down5. Check that Emerg. Stop alarm is shown on the TPOP.6. Try to step up both sides. It should not be possible!7. Restore the Emergency Stop CordNR12: Acknowledge the alarm on TPOP8. After 6 sec the Safety Relay activates9. Acknowledge the alarm so it disappears on the TPOP | 1.____2.____3.____4.____5.____6.____7.____8.____9.____ |
| F03S2203F03K0007NR12F03K0254 | Emergency Stop Cord S2 (PS2) Em Stop XL12NR12Em Stop Main Air | 1. Step up the machine to Air On 2. Pull the Emergency Stop Cord3. Check that the machine steps down in step zero 4. Check that the Safety Relay shut down5. Check that Emerg. Stop alarm is shown on the TPOP.6. Try to step up both sides. It should not be possible!7. Restore the Emergency Stop CordNR12: Acknowledge the alarm on TPOP8. After 6 sec the Safety Relay activates9. Acknowledge the alarm so it disappears on the TPOP | 1.____2.____3.____4.____5.____6.____7.____8.____9.____ |
Check of Safety Outputs for UV-Power
Pluto modules in El Cab| Pluto 3Q0, Q1 | Pluto 4 |
| F03K0014 | F03K0016 |
Safety Relays in El Cab| F03K0007 | F03K0008 | F03K0010 | F03K0011 | F03K0012 | F03K0013 |
| Em StopXL12 | CS XL21 | CS XL22 | PS XL31 | PS XL32 | Hydr Mot |
NR12| F03K1253 | F03K2253 | F03K0255 | F03K0254 |
| UV Lamp S1 | UV Lamp S2 | Hatch/CS Air | Em Stop Main Air |
Side 1
| Step | Perform following: | Check that: | Sign |
| 1 | Pull down the Hatches, on both sides, between Carton and Package Section | There is a steady green light on both Adam/E sensors LED | |
| 2 | Acknowledge all alarms on the TPOP so it is possible to step up the machine | Ladder flash in Air On | |
| 3 | Step up both sides to Air On | Ladder steady light in Air On | |
| Q0 and Q1 are lit on Pluto 3 | |
| 4 | Open a Door in Package Section S1 (P.S.1) | Both sides stay in Air On. | |
| TPOP show an open door in P.S.1. | |
| Q0 goes Off on Pluto 3 | |
| Safety Relays F03K0011 and F03K0012 shut downNR12:F03K1253 shut down | |
| 5 | Close the Door in P.S.1. | | |
| 6 | Reset the Door Guard alarm on TPOP. -After 6 seconds… | The Door Guard alarm disappear from TPOP | |
| Q0 activates on Pluto 3 | |
| Safety Relays F03K0011 and F03K0012 activatesNR12:F03K1253 activates | |
Side 2
| Step | Perform following: | Check that: | Sign |
| 1 | Pull down the Hatches, on both sides, between Carton and Package Section | There is a steady green light on both Adam/E sensors LED | |
| 2 | Acknowledge all alarms on the TPOP so it is possible to step up the machine | Ladder Flash in Air On | |
| 3 | Step up both sides to Air On | Ladder steady light in Air On | |
| Q0 and Q1 are lit on Pluto 3 | |
| 4 | Open a Door in Package Section S2 (P.S.2.) | Both sides stay in Air On. | |
| TPOP show an open door in P.S.2. | |
| Q1 goes Off on Pluto 3 | |
| Safety Relays F03K0011 and F03K0012 shut downNR12:F03K2253 shut down | |
| 5 | Close the Door in P.S.2. | | |
| 6 | Reset the Door Guard alarm on TPOP.-After 6 seconds… | The Door Guard alarm disappear from TPOP | |
| Q1 activates on Pluto 3 | |
| Safety Relays F03K0011 and F03K0012 activatesNR12:F03K2253 activates | |
Check of Safety Outputs for Paper Splice Board in ASU S1 and check of reset function before activation.
Pluto and Safety Relays in ASU El Cab| Safety Relay F03K1223Blocking Splice Board S1 |
| Safety Relay F03K2223Blocking Splice Board S2 |
| Pluto 5 F03K0024 |
Side 1
| Step | Perform following: | Check that: | Sign |
| 1 | Acknowledge all alarms on the TPOP so it is possible to step up the machine | Ladder Flash in Air On | |
| 2 | Step up both sides to Air On | Ladder steady light in Air On | |
| 3 | Open the Reel Door and the Hatch for Paper Splice Board on the ASU S1 | Both sides stay in Air On. | |
| (Safety Relay F03K1223 shut down) | |
| The Paper Splice Board on S1 can be moved by hand. (Put it back in start position). | |
| The Lamp in reset button ASU S1 lit | |
| 4 | Close the Reel Door and the Hatch for Paper Splice Board on the ASU S1 | The Lamp in reset button ASU S1 starts flashing | |
| 5 | Push the Reset Button on ASU S1 | The Lamp in reset button ASU S1 goes off | |
| (The Paper Splice Board S1 is locked to its end position and can not be moved by hand) | |
Side 2
| Step | Perform following: | Check that: | Sign |
| 1 | Acknowledge all alarms on the TPOP so it is possible to step up the machine | Ladder Flash in Air On | |
| 2 | Step up both sides to Air On | Ladder steady light in Air On | |
| 3 | Open the Reel Door and the Hatch for Paper Splice Board on the ASU S2 | Both sides stay in Air On. | |
| (Safety Relay F03K2223 shut down) | |
| The Paper Splice Board on S1 can be moved by hand. (Put it back in start position). | |
| The Lamp in reset button ASU S2 lit | |
| 4 | Close the Reel Door and the Hatch for Paper Splice Board on the ASU S2 | The Lamp in reset button ASU S2 starts flashing | |
| 5 | Push the Reset Button on ASU S2 | The Lamp in reset button ASU S2 goes off | |
| (The Paper Splice Board S2 is locked to its end position and can not be moved by hand) | |
Security Stop during Motor On
Emergency Stop| Step | Perform following: | Check that: | Sign |
| 1 | Acknowledge all alarms on the TPOP so it is possible to step up the machine | Ladder Flash in Air On | |
| 2 | Step up both sides to Tank Filling | The Machine goes through its homing sequence and the Ladder starts flashing in Motor On. | |
| 3 | Step up both sides to Motor On | Mandrel Wheel in C.S. moves. Cassette Conveyor in P.S. moves. Discharger in P.S. moves. | |
| 4 | When the Machine is running…Pull the Emergency Stop Cord | The Machine steps down to step zero | |
| All moving function stops within 1 second. | |
| 5 | Restore the Emergency Stop Cord | | |
| 6 | Acknowledge the Emergency Stop alarm (Hand) | The alarm disappear from TPOP | |
| 7 | Step up both sides to Air On | Ladder steady light in Air On | |
| 8 | Step down both sides to step zero | Ladder Flash in Air On | |
Package Section Doors| Step | Perform following: | Check that: | Sign |
| 1 | Acknowledge all alarms on the TPOP so it is possible to step up the machine | Ladder Flash in Air On | |
| 2 | Step up both sides to Tank Filling | The Machine goes through its homing sequence and the Ladder starts flashing in Motor On. | |
| 3 | Step up both sides to Motor On | Mandrel Wheel in C.S. moves. Cassette. Conveyor in P.S. moves. Discharger in P.S. moves | |
| 4 | When the Machine is running…Open a Door in Package Section | The Machine steps down to Preheating | |
| All moving function stops within 1 second. | |
| 5 | Close the Door | | |
| 6 | Acknowledge the Door alarm | The alarm disappear from TPOP | |
| 7 | Step down both sides to step zero | Ladder Flash in Air On | |
Carton Section Doors| Step | Perform following: | Check that: | Sign |
| 1 | Acknowledge all alarms on the TPOP so it is possible to step up the machine | Ladder Flash in Air On | |
| 2 | Step up both sides to Tank Filling | The Machine goes through its homing sequence and the Ladder starts flashing in Motor On. | |
| 3 | Step up both sides to Motor On | Mandrel Wheel in C.S. moves. Cassette Conveyor in P.S. moves. Discharger in P.S. moves | |
| 4 | When the Machine is running…Open a Door in Carton Section | The Machine steps down to Preheating | |
| All moving function stops within 1 second. | |
| 5 | Close the Door | | |
| 6 | Acknowledge the Door alarm | The alarm disappear from TPOP | |
| 7 | Step down both sides to step zero | Ladder Flash in Air On | |
Safety Switch - Set
| Equipment Status | Program Step |
Risk of serious personal injury.The machine contains many safety hazards while it is in operation. The machine must never be operated with the doors open and the door guards must under no circumstances be over-bridged.
- Remove the two Screw and the Sensor.
- Loosen the two Screw.
- Set the Bracket so the Sensor and the Non-contact safety sensor are separated with the distance A. Make sure that the Marker are aligned.
- Tighten the two Screw.
- Attach the Sensor and the two Screw.
- Repeat the procedure for all the door guards.
- Close the doors and make sure that the Sensor indicator is lit with a steady green light. If it is not the safety switch is incorrectly set.

A (mm) = Maximum 4
- Screw
- Sensor
- Screw
- Bracket
- Non-contact safety sensor
- Marker
- Sensor indicator
Safety Switches - Check
| Equipment Status | Program Step |
See Chapter Safety Precautions for locations of the safeguards.- Step up the machine to Pre-heating.
- Open a door and check that the TPOP ladder stops flashing.
- When the door is open, confirm that the corresponding door symbol on the TPOP appears and the yellow warning lamp is flashing. If not, replace the door safety switch and set it according to procedure Safety Switch - Set and perform a new check.
- Close the door.
- the yellow warning lamp shows a fixed light.
- Reset the alarm on the TPOP.
- the corresponding door symbol on the TPOP and the yellow warning lamp goes out.
- Repeat the item Reference to Reference on all doors.
For a more accurate test perform the TT/3 2000 safety system check as follows. Perform this test every time the safety system have been rebuilt, reconnected or if a component in the safety system have been replaced by another.
Check Service Switch Function
- Activate all Safety Relay (Service Switch in OFF position, left)
- Step the machine down to step zero.
| Perform following: | Check that: | Sign |
| Turn the Service Switch A01S0187 to ON position (right) | Only F03K0007 and F03K0013 are activated | |
| Turn the Service Switch A01S0187 till OFF position (left) | All Safety Relays are activated | |
The Service Switch must be switched Off (left) to continue the Safety System Check Procedure.
Check Door Guard Function
Check the Safety Relay Shutdown, the alarms on the TPOP, and the prevention of step up possibility.- Step the machine down to step zero.
- Make sure that the Hatches, on both sides, between Carton and Package Section are closed. If a Hatch is open, both Carton Section and Package Section Safety Relays will shut down when opening a door.
- Reset any alarm on the TPOP and step up the machine.
ASU, Carton Section, and CAU Doors
Pluto modules in El Cab| Pluto 3 | Pluto 4 |
| F03K0014 | F03K0016 |
Safety Relays in El Cab. (The non-shaded Relays will be tested).| F03K0007 | F03K0008 | F03K0010 | F03K0011 | F03K0012 | F03K0013 |
| Em Stop XL12 | CS XL21 | CS XL22 | PS XL31 | PS XL32 | Hydr Mot |
| Ref. Des: | Door Guard/Safety Relays | Perform and check | Sign |
| F03B1202 | ASU1 SA-Oven door | 1. Check that the Safety Relays are activated 2. Open and close the door 3. Check that the Safety Relays have shut down4. Try to step up both sides. It should not be possible!5. Check that actual door alarm is shown on the TPOP.6. Reset the alarm from the TPOP7. After 6 sec the Safety Relays activates8. Check that it's possible to step up both sides9. Check that both sides are in step zero | 1.____2.____3.____4.____5.____6.____7.____8.____9.____ |
| F03K0008 F03K0010 F03K0013 | CS XL21CS XL22CS Hydr. Motor | | |
| F03B2202 | ASU2 SA-Oven Door | 1. Open and close the door2. Check that the Safety Relays have shut down3. Try to step up both sides. It should not be possible!4. Check that actual door alarm is shown on the TPOP.5. Reset the alarm from the TPOP6. After 6 sec the Safety Relays activates7. Check that it's possible to step up both sides8. Check that both sides are in step zero | 1.____2.____3.____4.____5.____6.____7.____8.____ |
| F03K0008F03K0010F03K0013 | CS XL21 CS XL22 CS Hydr. Motor | | |
| F03B1213 | CS1 LFU Mandrel Wheel Door | 1. Open and close the door 2. Check that the Safety Relays have shut down3. Try to step up both sides. It should not be possible!4. Check that actual door alarm is shown on the TPOP.5. Reset the alarm from the TPOP6. After 6 sec the Safety Relays activates7. Check that it's possible to step up both sides8. Check that both sides are in step zero | 1.____2.____3.____4.____5.____6.____7.____8.____ |
| F03K0008 F03K0010 F03K0013 | CS XL21CS XL22 CS Hydr. Motor | | |
| F03B1214 | CS1 Sleeve Erector Door | 1. Open both doors.2. Close the locking door and leave the actual door open3. Reset the alarms on the TPOP.4. Check that actual door alarm is shown on the TPOP.5. Check that the Safety Relays shut down6. Try to step up both sides. It should not be possible!7. Close both doors8. Reset the alarm so it disappears on the TPOP9. After 6 sec the Safety Exp Relays activates10. Check that it is possible to step up both sides11. Check that both sides are in step zero | 1.____2.____3.____4.____5.____6.____7.____8.____9.____10.___11.___ |
| F03K0008 F03K0010 F03K0013 | CS XL21 CS XL22 CS Hydr. Motor | | |
| F03B1215 | CS1 TPOP Door | 1. Open both doors. 2. Close the locking door and leave the actual door open 3. Reset the alarms on the TPOP.4. Check that actual door alarm is shown on the TPOP.5. Check that the Safety Relays shut down6. Try to step up both sides. It should not be possible!7. Close both doors8. Reset the alarm so it disappears on the TPOP9. After 6 sec the Safety Exp Relays activates10. Check that it is possible to step up both sides11. Check that both sides are in step zero | 1.____2.____3.____4.____5.____6.____7.____8.____9.____10.___11.___ |
| F03K0008 F03K0010 F03K0013 | CS XL21 CS XL22 CS Hydr. Motor | |
| F03B1216 | CS1 Cutting Door | 1. Open and close the door2. Check that the Safety Relays have shut down3. Try to step up both sides. It should not be possible!4. Check that actual door alarm is shown on the TPOP.5. Reset the alarm from the TPOP6. After 6 sec the Safety Relays activates7. Check that it's possible to step up both sides 8. Check that both sides are in step zero | 1.____2.____3.____4.____5.____6.____7.____8.____ |
| F03K0008 F03K0010 F03K0013 | CS XL21 CS XL22 CS Hydr. Motor | | |
| F03B1201 | CAU1 Magazine Door (If CAU option) | 1. Open and close the door2. Check that the Safety Relays have shut down3. Try to step up both sides. It should not be possible!4. Check that actual door alarm is shown on the TPOP.5. Reset the alarm from the TPOP6. After 6 sec the Safety Relays activates7. Check that it's possible to step up both sides8. Check that both sides are in step zero | 1.____2.____3.____4.____5.____6.____7.____8.____ |
| F03K0008 F03K0010 F03K0013 | CS XL21 CS XL22 CS Hydr. Motor | | |
| F03B1209 | CS1 LFU Tools Door | 1. Open and close the door 2. Check that the Safety Relays have shut down3. Try to step up both sides. It should not be possible!4. Check that actual door alarm is shown on the TPOP.5. Reset the alarm from the TPOP6. After 6 sec the Safety Relays activates7. Check that it's possible to step up both sides8. Check that both sides are in step zero | 1.____2.____3.____4.____5.____6.____7.____8.____ |
| F03K0008 F03K0010 F03K0013 | CS XL21 CS XL22 CS Hydr. Motor | | |
| F03B1210 | CS1 LFU Extruder Door | 1. Open both doors.2. Close the locking door and leave the actual door open 3. Reset the alarms on the TPOP.4. Check that actual door alarm is shown on the TPOP.5. Check that the Safety Relays shut down6. Try to step up both sides. It should not be possible!7. Close both doors8. Reset the alarm so it disappears on the TPOP9. After 6 sec the Safety Exp Relays activates10. Check that it is possible to step up both sides11. Check that both sides are in step zero | 1.____2.____3.____4.____5.____6.____7.____8.____9.____10.___11.___ |
| F03K0008 F03K0010 F03K0013 | CS XL21 CS XL22 CS Hydr. Motor | | |
| F03B1211 | CS1 Water Circ. Door | 1. Open both doors.2. Close the locking door and leave the actual door open3. Reset the alarms on the TPOP.4. Check that actual door alarm is shown on the TPOP.5. Check that the Safety Relays shut down6. Try to step up both sides. It should not be possible!7. Close both doors8. Reset the alarm so it disappears on the TPOP9. After 6 sec the Safety Exp Relays activates10. Check that it is possible to step up both sides11. Check that both sides are in step zero | 1.____2.____3.____4.____5.____6.____7.____8.____9.____10.___11.___ |
| F03K0008 F03K0010 F03K0013 | CS XL21 CS XL22 CS Hydr. Motor | | |
| F03B1212 | CS1 Perox. Pump Door | 1. Open and close the door 2. Check that the Safety Relays have shut down3. Try to step up both sides. It should not be possible!4. Check that actual door alarm is shown on the TPOP.5. Reset the alarm from the TPOP6. After 6 sec the Safety Relays activates7. Check that it's possible to step up both sides8. Check that both sides are in step zero | 1.____2.____3.____4.____5.____6.____7.____8.____ |
| F03K0008 F03K0010 F03K0013 | CS XL21 CS XL22 CS Hydr. Motor | | |
| F03B2213 | CS2 LFU Mandrel Wheel Door | 1. Open both doors.2. Close the locking door and leave the actual door open3. Reset the alarms on the TPOP.4. Check that actual door alarm is shown on the TPOP.5. Check that the Safety Relays shut down6. Try to step up both sides. It should not be possible!7. Close both doors8. Reset the alarm so it disappears on the TPOP9. After 6 sec the Safety Exp Relays activates10. Check that it is possible to step up both sides11. Check that both sides are in step zero | 1.____2.____3.____4.____5.____6.____7.____8.____9.____10.___11.___ |
| F03K0008 F03K0010 F03K0013 | CS XL21 CS XL22 CS Hydr. Motor | | |
| F03B2214 | CS2 LFU Sleeve Erector Door | 1. Open and close the door2. Check that the Safety Relays have shut down3. Try to step up both sides. It should not be possible!4. Check that actual door alarm is shown on the TPOP.5. Reset the alarm from the TPOP6. After 6 sec the Safety Relays activates7. Check that it's possible to step up both sides8. Check that both sides are in step zero | 1.____2.____3.____4.____5.____6.____7.____8.____ |
| F03K0008 F03K0010 F03K0013 | CS XL21 CS XL22 CS Hydr. Motor | | |
| F03B2215 | CS2 TPOP Door | 1. Open both doors. 2. Close the locking door and leave the actual door open 3. Reset the alarms on the TPOP.4. Check that actual door alarm is shown on the TPOP.5. Check that the Safety Relays shut down6. Try to step up both sides. It should not be possible!7. Close both doors8. Reset the alarm so it disappears on the TPOP9. After 6 sec the Safety Exp Relays activates10. Check that it is possible to step up both sides11. Check that both sides are in step zero | 1.____2.____3.____4.____5.____6.____7.____8.____9.____10.___11.___ |
| F03K0008 F03K0010 F03K0013 | CS XL21 CS XL22 CS Hydr. Motor | | |
| F03B2216 | CS2 Cutting Door | 1. Open and close the door 2. Check that the Safety Relays have shut down3. Try to step up both sides. It should not be possible!4. Check that actual door alarm is shown on the TPOP.5. Reset the alarm from the TPOP6. After 6 sec the Safety Relays activates7. Check that it's possible to step up both sides8. Check that both sides are in step zero | 1.____2.____3.____4.____5.____6.____7.____8.____ |
| F03K0008 F03K0010 F03K0013 | CS XL21CS XL22 CS Hydr. Motor | | |
| F03B2201 | CAU2 Magazine Door (If CAU option) | 1. Open and close the door 2. Check that the Safety Relays have shut down3. Try to step up both sides. It should not be possible! 4. Check that actual door alarm is shown on the TPOP.5. Reset the alarm from the TPOP6. After 6 sec the Safety Relays activates7. Check that it's possible to step up both sides8. Check that both sides are in step zero | 1.____2.____3.____4.____5.____6.____7.____8.____ |
| F03K0008 F03K0010 F03K0013 | CS XL21 CS XL22 CS Hydr. Motor | | |
| F03B2209 | CS2 LFU Tools Door | 1. Open both doors. 2. Close the locking door and leave the actual door open3. Reset the alarms on the TPOP.4. Check that actual door alarm is shown on the TPOP.5. Check that the Safety Relays shut down6. Try to step up both sides. It should not be possible!7. Close both doors8. Reset the alarm so it disappears on the TPOP9. After 6 sec the Safety Exp Relays activates10. Check that it is possible to step up both sides11. Check that both sides are in step zero | 1.____2.____3.____4.____5.____6.____7.____8.____9.____10.___11.___ |
| F03K0008 F03K0010 F03K0013 | CS XL21 CS XL22 CS Hydr. Motor | | |
| F03B2210 | CS2 LFU Extruder Door | 1. Open and close the door2. Check that the Safety Relays have shut down3. Try to step up both sides. It should not be possible!4. Check that actual door alarm is shown on the TPOP.5. Reset the alarm from the TPOP6. After 6 sec the Safety Relays activates7. Check that it's possible to step up both sides8. Check that both sides are in step zero | 1.____2.____3.____4.____5.____6.____7.____8.____ |
| F03K0008 F03K0010 F03K0013 | CS XL21 CS XL22 CS Hydr. Motor | | |
| F03B2211 | CS2 Hydraulic Pump Door | 1. Open both doors. 2. Close the locking door and leave the actual door open3. Reset the alarms on the TPOP.4. Check that actual door alarm is shown on the TPOP.5. Check that the Safety Relays shut down6. Try to step up both sides. It should not be possible!7. Close both doors8. Reset the alarm so it disappears on the TPOP9. After 6 sec the Safety Exp Relays activates10. Check that it is possible to step up both sides11. Check that both sides are in step zero | 1.____2.____3.____4.____5.____6.____7.____8.____9.____10.___11.___ |
| F03K0008 F03K0010 F03K0013 | CS XL21 CS XL22 CS Hydr. Motor | | |
| F03B2212 | CS2 Hydraulic Motor Door | 1. Open and close the door 2. Check that the Safety Relays have shut down3. Try to step up both sides. It should not be possible!4. Check that actual door alarm is shown on the TPOP.5. Reset the alarm from the TPOP6. After 6 sec the Safety Relays activates7. Check that it's possible to step up both sides8. Check that both sides are in step zero | 1.____2.____3.____4.____5.____6.____7.____8.____ |
| F03K0008 F03K0010 F03K0013 | CS XL21 CS XL22 CS Hydr. Motor | | |
Package Section Doors
Safety Relays in El Cab. (The non-shaded Relays will be tested).| F03K0007 | F03K0008 | F03K0010 | F03K0011 | F03K0012 | F03K0013 |
| Em StopXL12 | CS XL21 | CS XL22 | PS XL31 | PS XL32 | Hydr Mot |
| Ref. Des: | Door Guard/Safety Relay | Perform and check | Sign |
| F03B1206 | PS1 Front Door | 1. Check that the Safety Relays are activated2. Open and close the door3. Check that the Safety Relays have shut down4. Try to step up both sides. It should not be possible!5. Check that actual door alarm is shown on the TPOP.6. Acknowledge the alarm from the TPOP7. After 6 sec the Safety Relays activates8. Check that it's possible to step up both sides9. Check that both sides are in step zero | 1.____2.____3.____4.____5.____6.____7.____8.____9.____ |
| F03K0011 F03K0012 | PS XL31 PS XL32 | | |
| F03B1217 | PS1 Bottom Sealing Door | 1. Open and close the door2. Check that the Safety Relays have shut down3. Try to step up both sides. It should not be possible!4. Check that actual door alarm is shown on the TPOP.5. Acknowledge the alarm from the TPOP6. After 6 sec the Safety Relays activates7. Check that it's possible to step up both sides8. Check that both sides are in step zero | 1.____2.____3.____4.____5.____6.____7.____8.____ |
| F03K0011 F03K0012 | PS XL31PS XL32 | | |
| F03B1218 | PS1 Filling Door | 1. Open and close the door2. Check that the Safety Relays have shut down3. Try to step up both sides. It should not be possible!4. Check that actual door alarm is shown on the TPOP.5. Acknowledge the alarm from the TPOP6. After 6 sec the Safety Relays activates7. Check that it's possible to step up both sides8. Check that both sides are in step zero | 1.____2.____3.____4.____5.____6.____7.____8.____ |
| F03K0011 F03K0012 | PS XL31 PS XL32 | | |
| F03B1207 | PS1 Discharger Door | 1. Open and close the door2. Check that the Safety Relays have shut down3. Try to step up both sides. It should not be possible!4. Check that actual door alarm is shown on the TPOP.5. Acknowledge the alarm from the TPOP6. After 6 sec the Safety Relays activates7. Check that it's possible to step up both sides8. Check that both sides are in step zero | 1.____2.____3.____4.____5.____6.____7.____8.____ |
| F03K0011 F03K0012 | PS XL31 PS XL32 | | |
| F03B1208 | PS1 Fill Lift Door | 1. Open both doors.2. Close the locking door and leave the actual door open3. Acknowledge the alarms on the TPOP.4. Check that actual door alarm is shown on the TPOP.5. Check that the Safety Relays shut down6. Try to step up both sides. It should not be possible!7. Close both doors8. Acknowledge the alarm so it disappears on the TPOP9. After 6 sec the Safety Exp Relays activates10. Check that it is possible to step up both sides11. Check that both sides are in step zero | 1.____2.____3.____4.____5.____6.____7.____8.____9.____10.___11.___ |
| F03K0011 F03K0012 | PS XL31PS XL32 | | |
| F03B2206 | PS2 Front Door | 1. Open and close the door2. Check that the Safety Relays have shut down3. Try to step up both sides. It should not be possible!4. Check that actual door alarm is shown on the TPOP.5. Acknowledge the alarm from the TPOP6. After 6 sec the Safety Relays activates7. Check that it's possible to step up both sides8. Check that both sides are in step zero | 1.____2.____3.____4.____5.____6.____7.____8.____ |
| F03K0011 F03K0012 | PS XL31 PS XL32 | | |
| F03B2217 | PS2 Bottom Sealing Door | 1. Open and close the door2. Check that the Safety Relays have shut down3. Try to step up both sides. It should not be possible!4. Check that actual door alarm is shown on the TPOP.5. Acknowledge the alarm from the TPOP6. After 6 sec the Safety Relays activates7. Check that it's possible to step up both sides8. Check that both sides are in step zero | 1.____2.____3.____4.____5.____6.____7.____8.____ |
| F03K0011 F03K0012 | PS XL31 PS XL32 | | |
| F03B2218 | PS2 Filling Door | 1. Open and close the door2. Check that the Safety Relays have shut down3. Try to step up both sides. It should not be possible!4. Check that actual door alarm is shown on the TPOP.5. Acknowledge the alarm from the TPOP6. After 6 sec the Safety Relays activates7. Check that it's possible to step up both sides8. Check that both sides are in step zero | 1.____2.____3.____4.____5.____6.____7.____8.____ |
| F03K0011 F03K0012 | PS XL31 PS XL32 | | |
| F03B2207 | PS2 Discharger Door | 1. Open both doors.2. Close the locking door and leave the actual door open3. Acknowledge the alarms on the TPOP.4. Check that actual door alarm is shown on the TPOP.5. Check that the Safety Relays shut down6. Try to step up both sides. It should not be possible!7. Close both doors8. Acknowledge the alarm so it disappears on the TPOP9. After 6 sec the Safety Exp Relays activates10. Check that it is possible to step up both sides11. Check that both sides are in step zero | 1.____2.____3.____4.____5.____6.____7.____8.____9.____10.___11.___ |
| F03K0011 F03K0012 | PS XL31 PS XL32 | | |
| F03B2208F03K0011 F03K0012 | PS2 Fill Lift Door PS XL31 PS XL32 | 1. Open and close the door2. Check that the Safety Relays have shut down3. Try to step up both sides. It should not be possible!4. Check that actual door alarm is shown on the TPOP.5. Acknowledge the alarm from the TPOP6. After 6 sec the Safety Relays activates7. Check that it's possible to step up both sides8. Check that both sides are in step zero | 1.____2.____3.____4.____5.____6.____7.____8.____ |
| |
Check that the door guard system act as a whole machine when a hatch between Carton and Package Section is open
- Step the machine down to step zero.
- Acknowledge any alarm on the TPOP and step up the machine.Safety Relays in El Cab. (The non-shaded Relays will be tested).
| F03K0007 | F03K0008 | F03K0010 | F03K0011 | F03K0012 | F03K0013 |
| Em Stop XL12 | CS XL21 | CS XL22 | PS XL31 | PS XL32 | Hydr Mot |
| Ref. Des: | Door Guard/Safety Relays | Perform and check | Sign |
| Any door on Carton Section S1 | 1. Put the Hatch between Carton Section and Package Section in open position on side 1 and in closed position on side 2.2. Acknowledge all alarms on the TPOP so it is possible to step up the machine.3. Check that all Safety Relays are activated4. Open and close the door5. Check that the Safety Relays for both Carton and Package Section have shut down6. Acknowledge the alarm from the TPOP7. After 6 sec the Safety Relays activates | 1.____2.____3.____4.____5.____6.____7.____ |
| F03K0008 F03K0010 F03K0011 F03K0012 F03K0013 | CS XL21 CS XL22 PS XL31 PS XL32 CS Hydr. Motor | | |
| Any door on Package Section S1 | 1. Put the Hatch between Carton Section and Package Section in open position on side 1 and in closed position on side 2.2. Acknowledge all alarms on the TPOP so it is possible to step up the machine.3. Check that all Safety Relays are activated4. Open and close the door5. Check that the Safety Relays for both Carton and Package Section have shut down6. Acknowledge the alarm from the TPOP7. After 6 sec the Safety Relays activates | 1.____2.____3.____4.____5.____6.____7.____ |
| F03K0008 F03K0010 F03K0011 F03K0012 F03K0013 | CS XL21 CS XL22 PS XL31 PS XL32 CS Hydr. Motor | | |
| Any door on Carton Section S2 | 1. Put the Hatch between Carton Section and Package Section in closed position on side 1 and in open position on side 2.2. Acknowledge all alarms on the TPOP so it is possible to step up the machine.3. Check that all Safety Relays are activated4. Open and close the door5. Check that the Safety Relays for both Carton and Package Section have shut down6. Acknowledge the alarm from the TPOP7. After 6 sec the Safety Relays activates | 1.____2.____3.____4.____5.____6.____7.____ |
| F03K0008 F03K0010 F03K0011 F03K0012 F03K0013 | CS XL21 CS XL22 PS XL31 PS XL32 CS Hydr.Motor | | |
| Any door on Package Section S2 | 1. Put the Hatch between Carton Section and Package Section in closed position on side 1 and in open position on side 2. 2. Acknowledge all alarms on the TPOP so it is possible to step up the machine.3. Check that all Safety Relays are activated4. Open and close the door5. Check that the Safety Relays for both Carton and Package Section have shut down6. Acknowledge the alarm from the TPOP7. After 6 sec the Safety Relays activates | 1.____2.____3.____4.____5.____6.____7.____ |
| F03K0008 F03K0010 F03K0011 F03K0012 F03K0013 | CS XL21 CS XL22 PS XL31 PS XL32 CS Hydr. Motor | | |
Check Emergency Stop Function
Check the Safety Relay Shutdown, the alarm on TPOP and the prevention of step up possibility.- Acknowledge any alarm on the TPOP and step up the machine.Safety Relays in El Cab. (The non-shaded Relay will be tested).
| vF03K0007 | F03K0008 | F03K0010 | F03K0011 | F03K0012 | F03K0013 |
| Em Stop XL12 | CS XL21 | CS XL22 | PS XL31 | PS XL32 | Hydr Mot |
Note: When F03K0007 shuts down, all others will also shut down!
| Ref. Des: | Emergency Stops/Safety Relay | Perform and check | Sign |
| F03S0018 | Emergency Stop Button on El Cabinet S1 | 1. Step up the machine to Air On 2. Push the Emergency Stop Button3. Check that the machine steps down in step zero4. Check that the Safety Relay shut down5. Check that Emerg. Stop alarm is shown on the TPOP.6. Try to step up both sides. It should not be possible!7. Release the Emergency Stop button8. After 6 sec the Safety Relay activates9. Acknowledge the alarm so it disappears on the TPOP | 1.____2.____3.____4.____5.____6.____7.____8.____9.____ |
| F03K0007 | Em Stop XL12 | | |
| F03S0019 | Emergency Stop Button on El Cabinet S2 | 1. Step up the machine to Air On2. Push the Emergency Stop Button3.Check that the machine steps down in step zero 4. Check that the Safety Relay shut down5. Check that Emerg. Stop alarm is shown on the TPOP.6. Try to step up both sides. It should not be possible!7. Release the Emergency Stop button8. After 6 sec the Safety Relay activates9. Acknowledge the alarm so it disappears on the TPOP | 1.____2.____3.____4.____5.____6.____7.____8.____9.____ |
| F03K0007 | Em Stop XL12 | | |
| F03S0205 | Emergency Stop Button on ASU | 1. Step up the machine to Air On2. Push the Emergency Stop Button3. Check that the machine steps down in step zero4. Check that the Safety Relay shut down5. Check that Emerg. Stop alarm is shown on the TPOP.6. Try to step up both sides. It should not be possible!7. Release the Emergency Stop button8. After 6 sec the Safety Relay activates9. Acknowledge the alarm so it disappears on the TPOP | 1.____2.____3.____4.____5.____6.____7.____8.____9.____ |
| F03K0007 | Em Stop XL12 | | |
| F03S1203 | Emergency Stop Cord S1 (PS1) | 1. Step up the machine to Air On 2. Pull the Emergency Stop Cord3. Check that the machine steps down in step zero4. Check that the Safety Relay shut down5. Check that Emerg. Stop alarm is shown on the TPOP.6. Try to step up both sides. It should not be possible!7. Restore the Emergency Stop Cord8. After 6 sec the Safety Relay activates9. Acknowledge the alarm so it disappears on the TPOP | 1.____2.____3.____4.____5.____6.____7.____8.____9.____ |
| F03K0007 | Em Stop XL12 | | |
| F03S2203 | Emergency Stop Cord S2 (PS2) | 1. Step up the machine to Air On 2. Pull the Emergency Stop Cord3. Check that the machine steps down in step zero 4. Check that the Safety Relay shut down5. Check that Emerg. Stop alarm is shown on the TPOP.6. Try to step up both sides. It should not be possible!7. Restore the Emergency Stop Cord8. After 6 sec the Safety Relay activates9. Acknowledge the alarm so it disappears on the TPOP | 1.____2.____3.____4.____5.____6.____7.____8.____9.____ |
| F03K0007 | Em Stop XL12 | |
Check of Safety Outputs for UV-Power
Pluto modules in El Cab| Pluto 3Q0, Q1 | Pluto 4 |
| F03K0014 | F03K0016 |
Safety Relays in El Cab| F03K0007 | F03K0008 | F03K0010 | F03K0011 | F03K0012 | F03K0013 |
| Em StopXL12 | CS XL21 | CS XL22 | PS XL31 | PS XL32 | Hydr Mot |
Side 1
| Step | Perform following: | Check that: | Sign |
| 1 | Pull down the Hatches, on both sides, between Carton and Package Section | There is a steady green light on both Adam/E sensors LED | |
| 2 | Acknowledge all alarms on the TPOP so it is possible to step up the machine | Ladder flash in Air On | |
| 3 | Step up both sides to Air On | Ladder steady light in Air On | |
| Q0 and Q1 are lit on Pluto 3 | |
| 4 | Open a Door in Package Section S1 (P.S.1) | Both sides stay in Air On. | |
| TPOP show an open door in P.S.1. | |
| Q0 goes Off on Pluto 3 | |
| Safety Relays F03K0011 and F03K0012 shut down | |
| 5 | Close the Door in P.S.1. | | |
| 6 | Reset the Door Guard alarm on TPOP. -After 6 seconds… | The Door Guard alarm disappear from TPOP | |
| Q0 activates on Pluto 3 | |
| Safety Relays F03K0011 and F03K0012 activates | |
Side 2
| Step | Perform following: | Check that: | Sign |
| 1 | Pull down the Hatches, on both sides, between Carton and Package Section | There is a steady green light on both Adam/E sensors LED | |
| 2 | Acknowledge all alarms on the TPOP so it is possible to step up the machine | Ladder Flash in Air On | |
| 3 | Step up both sides to Air On | Ladder steady light in Air On | |
| Q0 and Q1 are lit on Pluto 3 | |
| 4 | Open a Door in Package Section S2 (P.S.2.) | Both sides stay in Air On. | |
| TPOP show an open door in P.S.2. | |
| Q1 goes Off on Pluto 3 | |
| Safety Relays F03K0011 and F03K0012 shut down | |
| 5 | Close the Door in P.S.2. | | |
| 6 | Reset the Door Guard alarm on TPOP.-After 6 seconds… | The Door Guard alarm disappear from TPOP | |
| Q1 activates on Pluto 3 | |
| Safety Relays F03K0011 and F03K0012 activates | |
Check of Safety Outputs for Paper Splice Board in ASU S1 and check of reset function before activation.
Pluto and Safety Relays in ASU El Cab| Safety Relay F03K1223Blocking Splice Board S1 |
| Safety Relay F03K2223Blocking Splice Board S2 |
| Pluto 5 F03K0024 |
Side 1
| Step | Perform following: | Check that: | Sign |
| 1 | Acknowledge all alarms on the TPOP so it is possible to step up the machine | Ladder Flash in Air On | |
| 2 | Step up both sides to Air On | Ladder steady light in Air On | |
| 3 | Open the Reel Door and the Hatch for Paper Splice Board on the ASU S1 | Both sides stay in Air On. | |
| (Safety Relay F03K1223 shut down) | |
| The Paper Splice Board on S1 can be moved by hand. (Put it back in start position). | |
| The Lamp in reset button ASU S1 lit | |
| 4 | Close the Reel Door and the Hatch for Paper Splice Board on the ASU S1 | The Lamp in reset button ASU S1 starts flashing | |
| 5 | Push the Reset Button on ASU S1 | The Lamp in reset button ASU S1 goes off | |
| (The Paper Splice Board S1 is locked to its end position and can not be moved by hand) | |
Side 2
| Step | Perform following: | Check that: | Sign |
| 1 | Acknowledge all alarms on the TPOP so it is possible to step up the machine | Ladder Flash in Air On | |
| 2 | Step up both sides to Air On | Ladder steady light in Air On | |
| 3 | Open the Reel Door and the Hatch for Paper Splice Board on the ASU S2 | Both sides stay in Air On. | |
| (Safety Relay F03K2223 shut down) | |
| The Paper Splice Board on S1 can be moved by hand. (Put it back in start position). | |
| The Lamp in reset button ASU S2 lit | |
| 4 | Close the Reel Door and the Hatch for Paper Splice Board on the ASU S2 | The Lamp in reset button ASU S2 starts flashing | |
| 5 | Push the Reset Button on ASU S2 | The Lamp in reset button ASU S2 goes off | |
| (The Paper Splice Board S2 is locked to its end position and can not be moved by hand) | |
Security Stop during Motor On
Emergency Stop| Step | Perform following: | Check that: | Sign |
| 1 | Acknowledge all alarms on the TPOP so it is possible to step up the machine | Ladder Flash in Air On | |
| 2 | Step up both sides to Tank Filling | The Machine goes through its homing sequence and the Ladder starts flashing in Motor On. | |
| 3 | Step up both sides to Motor On | Mandrel Wheel in C.S. moves. Cassette Conveyor in P.S. moves. Discharger in P.S. moves. | |
| 4 | When the Machine is running…Pull the Emergency Stop Cord | The Machine steps down to step zero | |
| All moving function stops within 1 second. | |
| 5 | Restore the Emergency Stop Cord | | |
| 6 | Acknowledge the Emergency Stop alarm (Hand) | The alarm disappear from TPOP | |
| 7 | Step up both sides to Air On | Ladder steady light in Air On | |
| 8 | Step down both sides to step zero | Ladder Flash in Air On | |
Package Section Doors| Step | Perform following: | Check that: | Sign |
| 1 | Acknowledge all alarms on the TPOP so it is possible to step up the machine | Ladder Flash in Air On | |
| 2 | Step up both sides to Tank Filling | The Machine goes through its homing sequence and the Ladder starts flashing in Motor On. | |
| 3 | Step up both sides to Motor On | Mandrel Wheel in C.S. moves. Cassette. Conveyor in P.S. moves. Discharger in P.S. moves | |
| 4 | When the Machine is running…Open a Door in Package Section | The Machine steps down to Preheating | |
| All moving function stops within 1 second. | |
| 5 | Close the Door | | |
| 6 | Acknowledge the Door alarm | The alarm disappear from TPOP | |
| 7 | Step down both sides to step zero | Ladder Flash in Air On | |
Carton Section Doors| Step | Perform following: | Check that: | Sign |
| 1 | Acknowledge all alarms on the TPOP so it is possible to step up the machine | Ladder Flash in Air On | |
| 2 | Step up both sides to Tank Filling | The Machine goes through its homing sequence and the Ladder starts flashing in Motor On. | |
| 3 | Step up both sides to Motor On | Mandrel Wheel in C.S. moves. Cassette Conveyor in P.S. moves. Discharger in P.S. moves | |
| 4 | When the machine is running, open a door in the Carton Section | The Machine steps down to Preheating | |
| All moving function stops within 1 second. | |
| 5 | Close the door | | |
| 6 | Acknowledge the door alarm | The alarm disappear from TPOP | |
| 7 | Step down both sides to step zero | Ladder Flash in Air On | |
Railing - Tighten
| Equipment Status | Program Step |
Tighten the screws on the railing according to the tightening torques in the table below. | Pos in the illustration | Torque |
| 1 | 15 Nm |
| 2 | 187 Nm |

- Screw
- Screw
Emergency Stop Device
Emergency stop buttons and cords are placed symmetrically on both sides of the machine.For more information about the electrical safety system see Safety System.
A = Emergency Stop Cord
TT/3 Emergency Stop Button/Cord - Check
| Equipment Status | Program Step |
Check the emergency stop buttons and cords on the TT/3 Filling machine, see Emergency Stop Device for locations of the emergency stop buttons/cords.Note: Two service engineers co-operating makes this procedure work smoothly.Note: On some machines (Brazil) the emergency stop must be reset before the alarm can be acknowledged on the TPOP.- Step up the machine to tank filling.
- Inch the machine.
- While inching the machine, activate the emergency stop button/cord.
- Confirm that the machine drops to step zero, that the red warning lamp lights up (fixed light), and that the alarm appears on the TPOP. If not, replace the safety button/cord. A replaced cord must be set according to procedure Emergency Stop Cord - Set. Perform a new check.
- Acknowledge the alarm on the TPOP and make sure that the pneumatic system is depressurized.
- Reset the emergency stop button. The warning symbol and the red warning lamp turns off.
- Repeat the procedure, step a) to e), for all stop buttons and cords.
CSU Emergency Stop Button - Check
| Equipment Status | Program Step |
Check the emergency stop buttons, see page Emergency Stop Device for locations of the emergency stop buttons.- Check that the red warning lamp lights up (fixed light), and that the button for CAU turns red on the TPOP. Check that the blue warning lamp on the main machine lights up.
- Acknowledge the alarm on the TPOP.
- Reset the emergency stop button. The warning symbol and the red and blue warning lamps turn off.
GSU Emergency Stop Button - Check
| Equipment Status | Program Step |
Check the emergency stop buttons, see page Emergency Stop Device for locations of the emergency stop buttons.- While sucking of granulate is performed, activate the emergency stop button on the GSU.
- Confirm that the GSU stops and that the Red lamp under the emergency stop sign is lit and that the red warning lamp lights up (fixed light).
- Reset the emergency stop button.
- Push the Reset/Lamp Test button to reset the alarm.
- The red lamp under the emergency stop sign goes out.
- The red warning lamp goes out.

- Red lamp
- Reset/Lamp Test button
TTCU Emergency Stop Button - Check
| Equipment Status | Program Step |
Check the emergency stop button on the Hygiene Chamber Cleaning Unit (TTCU), see chapter Safety Precautions for locations of the emergency stop button.- Choose to run an alkali hygiene chamber cleaning (HCC) according to the OM (Operation Manual).
- While cleaning of the hygiene chamber is performed, activate the emergency stop button on the TTCU.
- Confirm that the TTCU stops and that the red lamp under the emergency stop sign is lit.
- Confirm that the filling machine drops to the program step air on, that the yellow warning lamp is lit with a flashing light, and that the alarm appears on the TPOP.
- If not, replace the TTCU safety button and perform a new check.
- Acknowledge the alarm on the TPOP.
- Reset the emergency stop button,
- the red lamp under the emergency stop sign goes out.
- the warning symbol on the TPOP and the yellow warning lamp on the filling machine goes out.
- Step up the machine and the hygiene chamber cleaning program continues.
Emergency Stop Cord - Set
| Equipment Status | Program Step air on |
- Turn Cam until the letter A is shown in the “window”. An emergency stop can now be triggered with a minimum of pull at the cord.
- Readjust the Cord tension device so that Activation pin is positioned in the middle between the cams. An emergency stop will now be triggered irrespective of whether the pulling force increases, Increased pulling force, or decreases, for instance in case the Cord brake.
- After an emergency stop, Position after an emergency stop, is the Activation pin not automatically free to move again. It have to be released by Release button situated at the front of the emergency stop.

- Cam
- Cord tension device
- Activation pin
- Cord brake
- Increased pulling force
- Position after an emergency stop
- Release button
Sequence Diagram Production
Sequence Diagram Production
Sequence Diagram Production
Electrical Supply - Lockout
| Equipment Status | Program Step step Zero |
| Special Equipment | Padlock Lockout hasp 90523-1761 |
Hazardous voltage can be present with the electrical supply disconnecting device in position O (OFF).Circuits identified by orange-coloured conductors are not disconnected by the main electrical supply disconnecting device. The location of the electrical supply disconnecting device of these circuits is described in the procedures that include work on these types of circuit.
- Turn the Electrical supply disconnecting device to position O (OFF).
- Push the Button and attach the Padlock . If several technicians are working on the machine, attach a Lockout hasp and then attach your padlock on the lockout hasp.Note: Each technician working on the equipment must attach their own padlock and retain the key in their possession until all work is completed.
- When your work is completed, remove your Padlock.
- When all technicians have completed their work, remove the Lockout hasp.

- Electrical supply disconnecting device
- Button
- Padlock
- Lockout hasp

The illustration shows the vision unit electrical supply disconnecting device and its location.Valid for Mecman machinesOnly valid for machines with
IC.

The illustration shows the vision unit electrical supply disconnecting device and its location.Valid for Festo machinesOnly valid for machines with
IC.
Valid for: Vision Unit 3652291-0100
Valid for: Equipment with CAUThe illustration shows the vision unit electrical supply disconnecting device and its location.

The illustration shows the
CSU electrical supply disconnecting device and its location.Only valid for machines with
IC.

The illustration shows the
GSU electrical supply disconnecting device and its location.

The illustration shows the
TTCU electrical supply disconnecting device and its location.

The illustration shows the
SRU electrical supply disconnecting device and its location. Valid for Opening Lokka.

The illustration shows the
SRU electrical supply disconnecting device and its location.Valid for SRU Version 1 and Version 2
Air Supply - Lockout
| Equipment Status | Program Step step zero |
| Special Equipment | Padlock Lockout hasp 90523-1761 |
Valid for Mecman
- On the main air valve, turn the Knob.
- Attach the Padlock. If several technicians are working on the equipment, attach a Lockout hasp 90523-1761 and then attach your padlock on the Lockout hasp 90523-1761.Note: Each technician working on the equipment must attach their own padlock and retain the key in their possession until all work is completed.
- To verify that all the compressed air has been released, check that the Pressure gauge shows the value 0(zero).
- When your work is completed, remove your Padlock.
- When all technicians have completed their work, remove the Lockout hasp 90523-1761.

- Padlock
- Knob
- Lockout hasp 90523-1761
- Pressure gauge
Valid for Festo
- On the main air valve, turn the Knob.
- Push the Button, and attach the Padlock. If several technicians are working on the equipment, attach a Lockout hasp 90523-1761, and then attach your Padlock on the Lockout hasp 90523-1761.Note: Each technician working on the equipment must attach their own padlock and retain the key in their possession until all work is completed.
- To verify that all the compressed air has been released, check that the Pressure gauge shows the value 0(zero).
- When your work is completed, remove your Padlock.
- When all technicians have completed their work, remove the Lockout hasp 90523-1761.

- Padlock
- Button
- Knob
- Lockout hasp 90523-1761
- Pressure gauge
Steam Supply - Lockout
| Equipment Status | Program Step step zero |
| Special Equipment | Padlock Lockout hasp 90523-1761 |
Main Steam Valve
- To close the Steam supply valve, turn the Handle so that it is perpendicular to the pipe.
- Push the lock slider inwards and attach the Padlock. If several technicians are working on the equipment, attach a Lockout hasp 90523-1761 and then attach your padlock on the Lockout hasp 90523-1761.Note: Each technician working on the equipment must attach their own padlock and retain the key in their possession until all work is completed.

- Steam supply valve
- Handle
- Padlock
- Lockout hasp 90523-1761
Hot steam.Turn off the supply valve and release any pressure in the steam system before starting any work on the machine or equipment.Pressurized steam can be discharged unexpectedly.
- To verify that all steam is released, check that the Pressure gauge, Pressure gauge, and Pressure gauge reads 0kPa (0bar).

- Steam supply valve
- Pressure gauge
- Pressure gauge
- Pressure gauge
- Pressure regulator
- When your work is completed, remove your padlock.
- When all technicians have completed their work, remove the lockout hasp.
TTCU Steam Valve
- Turn off the main steam supply by turning the Ball valve to closed position. Check that the Gauge reads 0kPa (0bar).

- Ball valve
- Gauge
Safety System Description
About the Safety System Description Chapter
This chapter contains information about the Safety System.General
Risk of death or serious injury.To ensure the performance of the safety related parts of the control system, any modifications must be performed such that there is no change in the status and integrity of the categories or performance levels of the applied safety functions.Any modifications that change the different categories or performance levels of the applied safety functions can lead to a dangerous failure in the safety system. The machine is equipped with a safety system containing emergency stops, interlocking door guards, and so on. Categories and performance level of the separate functions are given in Section
Emergency Stop and Safety Zones in the Machine.
Description of System
The safety system of the TT/3 is managed by the safety PLC:s. See the PLC table in Section List of Safety Components. The safety relay expansion modules are listed in the Relay Expansion Modules table in Section List of Safety Components.The machine is divided into several safety zones. When a door in any safety zone is opened, a signal is sent to the safety PLC, which will then take actions to put that zone into a safe state.When any emergency stop button is pressed on the machine, all the safety zones are put into a safe state.List of Safety Components
All components included in the safety system are listed in this section.Risk of death or serious injury.All safety components which are included in the safety system must be replaced with those components which are designated in the Spare Parts Catalogue.Replacement of safety components, which are included in the safety system, with components that are not designated in the Spare Parts Catalogue, can lead to a dangerous failure in the safety system.
| Reference designation | Description |
| Sensor |
| F03S0018 | Emergency stop Cabinet |
| F03S0019 | Emergency stop Cabinet |
| F03S1203 | Emergency stop Package Section |
| F03S2203 | Emergency stop Package Section |
| F03S0205 | Emergency stop ASU |
| F39S0201 | Emergency stop Cabinet CSU |
| V74S0042 | Emergency stop SRU |
| F73S0204 | Emergency stop Cabinet TTCU |
| F29S0001 | Emergency stop Cabinet GSU |
| F03B1202 | Door guard SA-oven door ASU side 1 |
| F03B1220 | Door guard hatch paper splice ASU side 1 |
| F03B1221 | Door guard reel doors ASU side 1 |
| F03B2202 | Door guard SA-oven door ASU side 2 |
| F03B2220 | Door guard hatch paper splice ASU side 2 |
| F03B2221 | Door guard reel doors ASU side 2 |
| F03B1213 | Door guard mandrel wheel Carton Section side 1 |
| F03B1214 | Door guard sleeve erector Carton Section side 1 |
| F03B1215 | Door guard TPOP Carton Section side 1 |
| F03B1216 | Door guard cutting Carton Section side 1 |
| F03B1201 | Door guard CAU Carton Section side 1 (IC) |
| F03B1209 | Door guard LFU tools Carton Section side 1 |
| F03B1210 | Door guard LFU extruder Carton Section side 1 |
| F03B1211 | Door guard water circulation Carton Section side 1 |
| F03B1212 | Door guard peroxide pump Carton Section side 1 |
| F03B2213 | Door guard mandrel wheel Carton Section side 2 |
| F03B2214 | Door guard sleeve erector Carton Section side 2 |
| F03B2215 | Door guard TPOP Carton Section side 2 |
| F03B2216 | Door guard cutting Carton Section side 2 |
| F03B2201 | Door guard CAU Carton Section side 2 (IC) |
| F03B2209 | Door guard LFU tools Carton Section side 2 |
| F03B2210 | Door guard LFU extruder Carton Section side 2 |
| F03B2211 | Door guard hydraulic pump Carton Section side 2 |
| F03B2212 | Door guard hydraulic motor Carton Section side 2 |
| F03B1219 | Door guard hatch Carton Section / Package section side 1 |
| F03B2219 | Door guard hatch Carton Section / Package section side 2 |
| F03B1206 | Door guard front Package Section side 1 |
| F03B1217 | Door guard bottom sealing Package Section side 1 |
| F03B1218 | Door guard filling door Package Section side 1 |
| F03B1207 | Door guard discharger Package Section side 1 |
| F03B1208 | Door guard fill lift Package Section side 1 |
| F03B2206 | Door guard front Package Section side 2 |
| F03B2217 | Door guard bottom sealing Package Section side 2 |
| F03B2218 | Door guard filling door Package Section side 2 |
| F03B2207 | Door guard discharger Package Section side 2 |
| F03B2208 | Door guard fill lift Package Section side 2 |
| Reference designation | Description |
| Input |
| F03K1231 | Connection block Carton Section side 1 |
| F03K1232 | Connection block Carton Section side 1 |
| F03B1246 | Connection plug Carton Section side 1 |
| F03B1247 | Connection plug Carton Section side 1 |
| F03B1248 | Connection plug Carton Section side 1 |
| F03K2231 | Connection block Carton Section side 2 |
| F03K2232 | Connection block Carton Section side 2 |
| F03B2246 | Connection plug Carton Section side 2 |
| F03B2247 | Connection plug Carton Section side 2 |
| F03B2248 | Connection plug Carton Section side 2 |
| F03K1229 | Connection block Package Section side 1 |
| F03B1243 | Connection plug Package Section side 1 |
| F03B1244 | Connection plug Package Section side 1 |
| F03B1245 | Connection plug Package Section side 1 |
| F03K2229 | Connection block Package Section side 2 |
| F03B2243 | Connection plug Package Section side 2 |
| F03B2244 | Connection plug Package Section side 2 |
| F03B2245 | Connection plug Package Section side 2 |
| Reference designation | Description |
| Logic |
| F03K0014 | Safety PLC Package Section |
| F03K0016 | Safety PLC Carton Section |
| F03K0024 | Safety PLC ASU |
| F73K0200 | Safety PLC TTCU |
| Reference designation | Description |
| Output |
| F03K1223 | Safety relay expansion module door guards ASU side 1 |
| F03K2223 | Safety relay expansion module door guards ASU side 2 |
| F03K1253 | Safety relay expansion module UV lamp Package Section side 1 (NR12) |
| F03K2253 | Safety relay expansion module UV lamp Package Section side 2 (NR12) |
| F03K0007 | Safety relay expansion module emergency stop |
| F03K0013 | Safety relay expansion module hydraulic pump |
| F03K0254 | Safety relay expansion module emergency stop |
| F03K0255 | Safety relay expansion module hatch Carton Section / Package Section (NR12) |
| F03K0011 | Safety relay expansion module safety door guard chain Package Section |
| F03K0012 | Safety relay expansion module delayed safety door guard chain Package Section servo |
| F03K0008 | Safety relay expansion module safety door guard chain Carton Section |
| F03K0010 | Safety relay expansion module delayed safety door guard chain Carton Section servo |
| F39K0203 | Safety relay expansion module CSU |
| V74F0040 | Safety relay expansion module SRU |
| V74F0041 | Safety relay expansion module SRU |
| F29K0002 | Safety relay expansion module GSU |
| Reference designation | Description |
| Actuator |
| F03K1263 | Safety valve ASU side 1 (NR12) |
| F03K2263 | Safety valve ASU side 2 (NR12) |
| F03K0260 | Safety valve main air inlet |
| F03K0266 | Safety valve hatch Carton Section |
| F03K0269 | Safety valve Package section |
| V60T3001 | Servo drive Filling side 1:1 |
| V60T4001 | Servo drive Filling side 1:2 |
| V60T5001 | Servo drive Filling side 2:1 |
| V60T6001 | Servo drive Filling side 2:2 |
| T21T0016 | Servo drive Record Player |
| A30T1001 | Servo drive Mandrel Wheel side 1 |
| A30T1004 | Servo drive LFU Tools side 1 |
| T12T1003 | Servo drive Paper Feed side 1 |
| G31T3007 | Servo drive Capper side 1:1 (IC) |
| G31T4007 | Servo drive Capper side 1:2 (IC) |
| A30T2001 | Servo drive Mandrel Wheel side 2 |
| A30T2004 | Servo drive LFU Tools side 2 |
| T12T2003 | Servo drive Paper Feed side 2 |
| G31T5007 | Servo drive Capper side 2:1 (IC) |
| G31T6007 | Servo drive Capper side 2:2 (IC) |
| G31T1006 | Servo drive Magazine side 1 (IC) |
| G31T2006 | Servo drive Magazine side 2 (IC) |
| G31T1008 | Servo drive Stripper side 1 (IC) |
| G31T2008 | Servo drive Stripper side 2 (IC) |
| G31T1009 | Servo drive Cap Lift side 1 (IC) |
| G31T2009 | Servo drive Cap Lift side 2 (IC) |
| G50T0001 | Servo drive Conveyor |
| V60T1002 | Servo drive Filling Lifter side 1 |
| V63T1001 | Servo drive Bottom Seal Lifter side 1 |
| V63T1002 | Servo drive Bottom Seal Horn side 1 |
| G65T001 | Servo drive Discharger |
| V60T2002 | Servo drive Filling Lifter side 2 |
| V63T2001 | Servo drive Bottom Seal Lifter side 2 |
| V63T2002 | Servo drive Bottom Seal Horn side 2 |
| G65T0010 | Servo drive Outfeed Side Pusher |
| V63Q1007 | Contactor Ultra-Sonic-Generator side 1 |
| V63Q2007 | Contactor Ultra-Sonic-Generator side 2 |
| T10Q0007 | Contactor Splicing |
| A30Q1006 | Contactor Granulate Screw Motor side 1 |
| A30Q2006 | Contactor Granulate Screw Motor side 2 |
| G70Q0001 | Contactor Belt Drive & DE Conveyor side 1 and 2 |
| G70Q1002 | Contactor Belt Drive side 1 |
| G70Q2002 | Contactor Belt Drive side 2 |
| G70Q1003 | Contactor DE Conveyor side 1 |
| G70Q2003 | Contactor DE Conveyor side 2 |
| A01Q0083 | Contactor F/C ASU, Carton Section, CAU |
| A01Q0084 | Contactor F/C Slack ASU, Carton Section Sleeve, CAU side 1 |
| A01Q0082 | Contactor F/C Slack ASU, Carton Section Sleeve, CAU side 2 |
| G65Q0009 | Contactor F/C Package Section |
| G65Q1003 | Contactor F/C Outfeeder Package Section side 1 |
| G65Q2003 | Contactor F/C Outfeeder Package Section side 2 |
| A24Q0003 | Contactor Hydraulic Pump |
| A24Q0004 | Contactor Hydraulic Pump |
| V67Q0001 | Contactor Cleaning Return Pump |
| V51K1020 | Contactor Peroxide Pump side 1 |
| V51K2020 | Contactor Peroxide Pump side 2 |
| T21Q1006 | Contactor Heater LS side 1 |
| T21Q2006 | Contactor Heater LS side 2 |
| V51Q1043 | Contactor UV Power side 1 |
| V51Q2043 | Contactor UV Power side 2 |
| V51Q1013 | Contactor UV Power side 1 |
| V51Q2013 | Contactor UV Power side 2 |
| V51Q1014 | Contactor UV Full Power side 1 |
| V51Q2014 | Contactor UV Full Power side 2 |
Service Mode
The service mode is used to do the settings in the LFU, the Peroxide System and for the Regulator Valve, Tank Level that requires that the air and hydraulic pressure is on. To activate the service mode, turn the Service switch using service key and follow the instructions in section:- 2.10.4-2.7 Peroxide System - Set TPOP
- 3.1-2.2 LFU - Basic Set
- 3.1-11.1 LFU Remote Control - Handle
- 3.7.1-2.3 Hot Channel - Final Set of Plastic Dosing
- 3.7.1-5.1 Hot Channel - Remove
- 3.7.1-7.2 Hot Channel - Change Needle
- 3.7.1-10.1 Hot Channel - Install
- 3.7.2-7.1 Guide Hot Channel - Change Distance Cylinders
- 3.12.2-2.1 External Tools - Set Centre of Tools
- 3.13.3-11.1 Hydraulic System LFU - Bleed
- 6.3.1-8.1 Regulator Valve, Tank Level - Overhaul (Valid for Valves: F450 and F451)

- Service switch
Safety System Architecture
The following are the different safety zones in the machine:The illustration shows how the different door guards are grouped and how they affect the actuators in the different parts of the machine.
- Emergency stops
- Door guards ASU side 1
- Door guards ASU side 2
- Door guards Carton Section
- Door guards Package Section
- Door guards Package Section side 1
- Door guards Package Section side 2
- Emergency stop power actuators
- Emercengy stop L12
- ASU Side Feeder side 1
- ASU Side Feeder side 2
- Carton Section L21, L22
- Carton Section Hydraulic pump
- Hatches Carton section / Package section
- Package Section L31, L32
- UV Power side 1
- UV Power side 2
Emergency Stop and Safety Zones in the Machine
Location of Emergency Stop Buttons

The illustration shows the non USA/Canada variant and
XH with
IC.
CSUOnly valid for variant with
IC.
GSU
TTCU
SRU
Location of Emergency Stop Wires

- Emergency Stop wire

The illustration shows the non USA/Canada variant and
XH with
IC.
Description
The emergency stop disconnects the power to all power loads outside the electrical cabinets, with the exception of the light fixtures and the HEPA systems, and the air pressure is removed from all moving parts.On IEC and UL-CSA, the Safety System will reset automatically when the actuated emergency stop is restored.On NR12, the safety system can be reset on the TPOP after the actuated emergency stop has been restored.Parts in the SRP/CS
The SRP/CS of Emergency Stop has the following architecture categories, performance levels, stop categories, SRP/CS response times, and the applicable fault exclusions.SRP/CS Diagrammatic Presentation
The following is a diagrammatic presentation of the safety functions realised by the SRP/CS described in Section Parts in the SRP/CS. | SRP/CSA | → | SRP/CSB | → | SRP/CSC | → | SRP/CSD | → | SRP/CSE | → | SRP/CSF | |
| | | | | | | | | | | | |
| S | | I | | B | | L | | O | | A | |
| No. | Sensor (S) | Input (I) | Bridge (B) | Logic (L) | Output (O) | Actuator (A) |
| 1 | Two channel emergency stop button with electronic pulsating signal | N/A | N/A | Safety PLC with cross channel monitoring of CPU, inputs and outputs | Safety relay expansion module with internal two channel disconnection | Two contactors with feedback loop |
| 2 | Two channel emergency stop button with electronic pulsating signal | N/A | N/A | Safety PLC with cross channel monitoring of CPU, inputs and outputs | Safety relay expansion module with internal two channel disconnection | Two contactors with feedback loop |
| 3 | Two channel emergency stop button with electronic pulsating signal | N/A | N/A | Safety PLC with cross channel monitoring of CPU, inputs and outputs | Safety relay expansion module with internal two channel disconnection | Safety valve and separate pressure guard for diagnostics |
| 4 | Two channel emergency stop button with electronic pulsating signal | N/A | N/A | Safety PLC with cross channel monitoring of CPU, inputs and outputs | Safety relay expansion module with internal two channel disconnection | Safety valve and separate pressure guard for diagnostics |
| 5 | Two channel emergency stop button with electronic pulsating signal | N/A | N/A | Safety PLC with cross channel monitoring of CPU, inputs and outputs | Safety relay expansion module with internal two channel disconnection | Servo drive with dual channel Safe Torque Off |
| 6 | Two channel emergency stop button with electronic pulsating signal | N/A | N/A | Safety PLC with cross channel monitoring of CPU, inputs and outputs | Safety relay expansion module with internal two channel disconnection | Servo drive with dual channel Safe Torque Off |
ASU Side 1: Material Web Splice Side Feeder
Location of Door guards in ASU Side 1 Material Web Splice

The illustration shows the non USA/Canada variant and XH with IC
Description
If any of the indicated doors in the safety zone is opened, the air pressure is removed from the ASU Side Feeder side 1.After opening the rear doors, the material web splice function can be reset manually. This is done with the reset button, placed between the rear doors.After opening the protective glass inside the side door, the safety system can be reset by using the reset button on the TPOP.Parts in the SRP/CS
The SRP/CS of Emergency Stop has the following architecture categories, performance levels, stop categories, SRP/CS response times, and the applicable fault exclusions.| No. | SRP/CS | StandardArchitecture / Performance Level | Stop Category | SRP/CS Response Time | Fault Exclusions |
| 1 | Safety related stop function of valves | EN ISO 13849-1:2006Category 1 / PL c | 0 | < 52 ms | Fault Exclusion Short Circuit Inside Cabinet |
SRP/CS Diagrammatic Presentation
These are the safety functions realised by the SRP/CS. | SRP/CSA | → | SRP/CSB | → | SRP/CSC | → | SRP/CSD | → | SRP/CSE | → | SRP/CSF | |
| | | | | | | | | | | | |
| S | | I | | B | | L | | O | | A | |
| No. | Sensor (S) | Input (I) | Bridge (B) | Logic (L) | Output (O) | Actuator (A) |
| 1 | Non-contact safety switch | N/A | N/A | Safety PLC with cross channel monitoring of CPU, inputs and outputs | Safety relay expansion module with internal two channel disconnection | Valves |
ASU Side 2: Material Web Splice Side Feeder
Location of Door guards in ASU side 2 Material Web Splice

The illustration shows the non USA/Canada variant and XH with IC
Description
If any of the indicated doors in the safety zone is opened, the air pressure is removed from the ASU Side Feeder side 2.After opening the rear doors, the material web splice function can be reset manually. This is done with the reset button, placed between the rear doors.After opening the protective glass inside the side door, the safety system can be reset by using the reset button on the TPOP.Parts in the SRP/CS
The SRP/CS of Emergency Stop has the following architecture categories, performance levels, stop categories, SRP/CS response times, and the applicable fault exclusions.| No. | SRP/CS | StandardArchitecture / Performance Level | Stop Category | SRP/CS Response Time | Fault Exclusions |
| 1 | Safety related stop function of valves | EN ISO 13849-1:2006Category 1 / PL c | 0 | < 52 ms | Fault Exclusion Short Circuit Inside Cabinet |
SRP/CS Diagrammatic Presentation
These are the safety functions realised by the SRP/CS. | SRP/CSA | → | SRP/CSB | → | SRP/CSC | → | SRP/CSD | → | SRP/CSE | → | SRP/CSF | |
| | | | | | | | | | | | |
| S | | I | | B | | L | | O | | A | |
| No. | Sensor (S) | Input (I) | Bridge (B) | Logic (L) | Output (O) | Actuator (A) |
| 1 | Non-contact safety switch | N/A | N/A | Safety PLC with cross channel monitoring of CPU, inputs and outputs | Safety relay expansion module with internal two channel disconnection | Valves |
Location of Door guards in Carton Section

Machine side 1The illustration shows the non USA/Canada variant and XH with IC

Machine side 2The illustration shows the non USA/Canada variant and XH with IC
Description
If any of the indicated doors in the safety zone is opened, the hydralic pressure is removed and the air pressure will be removed from the heater unit lifting valves, discharger mailbox valves, prefolder valves, LFU accessories valves and hygienic cleaning doors valves. Servo motors will be set to their safe state and the power will be removed for record player servo motor, paper slack servo motors, paper feed servo motors, sleeve conveyer servo motors, stripper servo motors, cap applicator servo motors, magazine servo motors, capper lifter servo motors, mandrel wheel and LFU tools servo motors.Carton Section and Package Section becomes a common zone when the hygienic cleaning doors are open. See description in Package Section.The safety system can be reset manually from the reset button on the TPOP.Parts in the SRP/CS
The SRP/CS of Emergency Stop has the following architecture categories, performance levels, stop categories, SRP/CS response times, and the applicable fault exclusions.SRP/CS Diagrammatic Presentation
These are the safety functions realised by the SRP/CS. | SRP/CSA | → | SRP/CSB | → | SRP/CSC | → | SRP/CSD | → | SRP/CSE | → | SRP/CSF | |
| | | | | | | | | | | | |
| S | | I | | B | | L | | O | | A | |
| No. | Sensor (S) | Input (I) | Bridge (B) | Logic (L) | Output (O) | Actuator (A) |
| 1 | Non-contact safety switch | N/A | N/A | Safety PLC with cross channel monitoring of CPU, inputs and outputs | Safety relay expansion module with internal two channel disconnection | Two contactors with feedback loop |
| 2 | Non-contact safety switch | Connection block | N/A | Safety PLC with cross channel monitoring of CPU, inputs and outputs | Safety relay expansion module with internal two channel disconnection | Two contactors with feedback loop |
| 3 | Non-contact safety switch | Connection block | N/A | Safety PLC with cross channel monitoring of CPU, inputs and outputs | Safety relay expansion module with internal two channel disconnection | Servo drive with dual channel Safe Torque Off |
| 4 | Non-contact safety switch | Connection block | N/A | Safety PLC with cross channel monitoring of CPU, inputs and outputs | Safety relay expansion module with internal two channel disconnection | Servo drives with dual channel Safe Torque Off |
| 5 | Non-contact safety switch | Connection block | N/A | Safety PLC with cross channel monitoring of CPU, inputs and outputs | Safety relay expansion module with internal two channel disconnection | Safety valve and separate pressure guard for diagnostics |
| 6 | Non-contact safety switch | Connection block | N/A | Safety PLC with cross channel monitoring of CPU, inputs and outputs | Safety relay expansion module with internal two channel disconnection | Two contactors with feedback loop |
| 7 | Non-contact safety switch | Connection block | N/A | Safety PLC with cross channel monitoring of CPU, inputs and outputs | Safety relay expansion module with internal two channel disconnection | Two contactors with feedback loop |
| 8 | Non-contact safety switch | Connection block | N/A | Safety PLC with cross channel monitoring of CPU, inputs and outputs | Safety relay expansion module with internal two channel disconnection | Safety valve and separate pressure guard for diagnostics |
| 9 | Non-contact safety switch | Connection block | N/A | Safety PLC with cross channel monitoring of CPU, inputs and outputs | Safety relay expansion module with internal two channel disconnection | Servo drives with dual channel Safe Torque Off |
| 10 | Non-contact safety switch | Connection block | N/A | Safety PLC with cross channel monitoring of CPU, inputs and outputs | Safety relay expansion module with internal two channel disconnection | Two contactors with feedback loop |
Location of Door guards in Package Section

View from machine side 1The illustration shows the non USA/Canada variant and XH with IC

View from machine side 2The illustration shows the non USA/Canada variant and XH with IC
Description
If any of the indicated doors in the safety zone is opened, the air pressure will be removed from cleaning lid valves, infeed cassette centration valves, casette volume change valves, flap folder valves, outpusher valves, aborter gate valves, and the hygienic cleaning doors valves. Servo motors will be set to their safe state and the power till be removed from the discharger servo motor, filling lifter servo motors, bottom sealing horn servo motors, bottom sealing lifter servo motors, conveyor servo motor, side pusher and outfeeder servo motors.Carton Section and Package Section becomes a common zone when the hygienic cleaning doors are open. See description in Carton Section.The safety system can be reset manually from the reset button on the TPOP.Parts in the SRP/CS
The SRP/CS of Emergency Stop has the following architecture categories, performance levels, stop categories, SRP/CS response times, and the applicable fault exclusions.SRP/CS Diagrammatic Presentation
These are the safety functions realised by the SRP/CS. | SRP/CSA | → | SRP/CSB | → | SRP/CSC | → | SRP/CSD | → | SRP/CSE | → | SRP/CSF | |
| | | | | | | | | | | | |
| S | | I | | B | | L | | O | | A | |
| No. | Sensor (S) | Input (I) | Bridge (B) | Logic (L) | Output (O) | Actuator (A) |
| 1 | Non-contact safety switch | Connection block | N/A | Safety PLC with cross channel monitoring of CPU, inputs and outputs | Safety relay expansion module with internal two channel disconnection | Safety valve and separate pressure guard for diagnostics |
| 2 | Non-contact safety switch | Connection block | N/A | Safety PLC with cross channel monitoring of CPU, inputs and outputs | Safety relay expansion module with internal two channel disconnection | Servo drives with dual channel Safe Torque Off |
| 3 | Non-contact safety switch | Connection block | N/A | Safety PLC with cross channel monitoring of CPU, inputs and outputs | Safety relay expansion module with internal two channel disconnection | Safety valve and separate pressure guard for diagnostics |
| 4 | Non-contact safety switch | Connection block | N/A | Safety PLC with cross channel monitoring of CPU, inputs and outputs | Safety relay expansion module with internal two channel disconnection | Servo drives with dual channel Safe Torque Off |
| 5 | Non-contact safety switch | Connection block | N/A | Safety PLC with cross channel monitoring of CPU, inputs and outputs | Safety relay expansion module with internal two channel disconnection | Safety valve and separate pressure guard for diagnostics |
| 6 | Non-contact safety switch | Connection block | N/A | Safety PLC with cross channel monitoring of CPU, inputs and outputs | Safety relay expansion module with internal two channel disconnection | Safety valve and separate pressure guard for diagnostics |
| 7 | Non-contact safety switch | Connection block | N/A | Safety PLC with cross channel monitoring of CPU, inputs and outputs | Safety relay expansion module with internal two channel disconnection | Servo drive with dual channel Safe Torque Off |
| 8 | Non-contact safety switch | Connection block | N/A | Safety PLC with cross channel monitoring of CPU, inputs and outputs | Safety relay expansion module with internal two channel disconnection | Safety valve and separate pressure guard for diagnostics |
| 9 | Non-contact safety switch | Connection block | N/A | Safety PLC with cross channel monitoring of CPU, inputs and outputs | Safety relay expansion module with internal two channel disconnection | Safety valve and separate pressure guard for diagnostics |
| 10 | Non-contact safety switch | Connection block | N/A | Safety PLC with cross channel monitoring of CPU, inputs and outputs | Safety relay expansion module with internal two channel disconnection | Servo drive with dual channel Safe Torque Off |
| 11 | Non-contact safety switch | Connection block | N/A | Safety PLC with cross channel monitoring of CPU, inputs and outputs | Safety relay expansion module with internal two channel disconnection | Safety valve and separate pressure guard for diagnostics |
| 12 | Non-contact safety switch | Connection block | N/A | Safety PLC with cross channel monitoring of CPU, inputs and outputs | Safety relay expansion module with internal two channel disconnection | Two contactors with feedback loop |
| 13 | Non-contact safety switch | Connection block | N/A | Safety PLC with cross channel monitoring of CPU, inputs and outputs | Safety relay expansion module with internal two channel disconnection | Safety valve and separate pressure guard for diagnostics |
| 14 | Non-contact safety switch | Connection block | N/A | Safety PLC with cross channel monitoring of CPU, inputs and outputs | N/A | Contactor with feedback loop |
Package Section UV-Lamp on Side 1
Location of Door guards in Package Section UV-Lamp on Side 1

The illustration shows the non USA/Canada variant and XH with IC
Description
If any of the indicated doors in the safety zone is opened everything mentioned in Package Section occurs, and the power to the UV-Lamp is removed on Side 1 only.The safety system can be reset manually from the reset button on the TPOP.Parts in the SRP/CS
The SRP/CS of Emergency Stop has the following architecture categories, performance levels, stop categories, SRP/CS response times, and the applicable fault exclusions.| No. | SRP/CS | StandardArchitecture / Performance Level | Stop Category | SRP/CS Response Time | Fault Exclusions |
| 1 | Safety related stop function of contactors | EN ISO 13849-1:2006Category 3 / PL e | 0 | < 55 ms | Fault Exclusion Short Circuit Inside Cabinet |
SRP/CS Diagrammatic Presentation
These are the safety functions realised by the SRP/CS. | SRP/CSA | → | SRP/CSB | → | SRP/CSC | → | SRP/CSD | → | SRP/CSE | → | SRP/CSF | |
| | | | | | | | | | | | |
| S | | I | | B | | L | | O | | A | |
| No. | Sensor (S) | Input (I) | Bridge (B) | Logic (L) | Output (O) | Actuator (A) |
| 1 | Non-contact safety switch | Connection block | N/A | Safety PLC with cross channel monitoring of CPU, inputs and outputs | Safety relay expansion module with internal two channel disconnection | Two contactors with feedback loop |
Package Section UV-Lamp on Side 2
Location of Door guards in Package Section UV-Lamp on Side 2

The illustration shows the non USA/Canada variant and XH with IC
Description
If any of the indicated doors in the safety zone is opened everything mentioned in Package Section occurs, and the power to the UV-Lamp is removed on Side 2 only.The safety system can be reset manually from the reset button on the TPOP.Parts in the SRP/CS
The SRP/CS of Emergency Stop has the following architecture categories, performance levels, stop categories, SRP/CS response times, and the applicable fault exclusions.| No. | SRP/CS | StandardArchitecture / Performance Level | Stop Category | SRP/CS Response Time | Fault Exclusions |
| 1 | Safety related stop function of contactors | EN ISO 13849-1:2006Category 3 / PL e | 0 | < 55 ms | Fault Exclusion Short Circuit Inside Cabinet |
SRP/CS Diagrammatic Presentation
These are the safety functions realised by the SRP/CS. | SRP/CSA | → | SRP/CSB | → | SRP/CSC | → | SRP/CSD | → | SRP/CSE | → | SRP/CSF | |
| | | | | | | | | | | | |
| S | | I | | B | | L | | O | | A | |
| No. | Sensor (S) | Input (I) | Bridge (B) | Logic (L) | Output (O) | Actuator (A) |
| 1 | Non-contact safety switch | Connection block | N/A | Safety PLC with cross channel monitoring of CPU, inputs and outputs | Safety relay expansion module with internal two channel disconnection | Two contactors with feedback loop |
Location of Emergency Stop for TTCU
Description
The emergency stop disconnects the power to the pressure pump and the desinfectant pump. The safety system can be reset manually from the reset button on the TTCU.Parts in the SRP/CS
The SRP/CS of Emergency Stop has the following architecture categories, performance levels, stop categories, SRP/CS response times, and the applicable fault exclusions.| No. | SRP/CS | StandardArchitecture / Performance Level | Stop Category | SRP/CS Response Time | Fault Exclusions |
| 1 | Safety related stop function of contactor | EN ISO 13849-1:2006Category 3 / PL e | 0 | < 45 ms | Fault Exclusion Short Circuit Inside Cabinet |
SRP/CS Diagrammatic Presentation
These are the safety functions realised by the SRP/CS. | SRP/CSA | → | SRP/CSB | → | SRP/CSC | → | SRP/CSD | → | SRP/CSE | → | SRP/CSF | |
| | | | | | | | | | | | |
| S | | I | | B | | L | | O | | A | |
| No. | Sensor (S) | Input (I) | Bridge (B) | Logic (L) | Output (O) | Actuator (A) |
| 1 | Non-contact safety switch | Connection block | N/A | Safety PLC with cross channel monitoring of CPU, inputs and outputs | N/A | Contactor with feedback loop |
General
The integrity of the safety system is based on the fault exclusions given in the following subsections.Risk of death or serious injury.Ensure that all the listed conditions for the fault exclusion are fulfilled.Altering the conditions given in the fault conditions will lead to a hazardous situation.
Fault Exclusion Short Circuit Inside Cabinet
A fault exclusion has been made inside the electrical cabinet for short-circuits between conductors.To maintain the justification and the safety performance level, the following conditions must be fulfilled:- The electrical cabinet must be kept locked, with access restricted to skilled or instructed persons.
- The protective bonding circuit must be maintained.
- The degree of protection of the electrical cabinet must not be reduced so that there is a risk of ingress of water or dust below the prior level of protection.
- The lids of the cable ducts must be restored after maintenance.
Emergency Stop - Check
| Equipment Status | Power must be turn ON.
|
The locations of the emergency stop buttons can be found in Section Location of Emergency Stop Buttons.- Identify the emergency stop button(s) to be tested. Perform the checks for the following:
- In the electrical cabinet, check on the safety PLC that the corresponding Input LED is lit.
- Press the emergency stop button.
- Check that the button remains in the pushed-in position.
- Check that the corresponding Input LED is no longer lit.
- Reset the emergency stop button by turning it slightly to the left.
- Check that the corresponding Input LED is lit up again.
- Repeat from step Reference for each emergency stop button.
Emergency Stop - TT/3
- Perform checks for the emergency stop button(s) in the table.For instructions, see page Reference.

- Safety PLC F03K0014
- I0
- I1
Emergency Stop - TTCU
- Perform checks for the emergency stop button(s) in the table.For instructions, see page Reference.

- Safety PLC F73K0200
- I0
- I1
Emergency Stop - CSU
- Perform checks for the emergency stop button(s) in the table.For instructions, see page Reference.

- Safety PLC F39K0203
- In1
- In 2
Emergency Stop - GSU
- Perform checks for the emergency stop button(s) in the table.For instructions, see page Reference.

- Safety PLC F29K0002
- In2
Emergency Stop - Sprue Remover
- Perform checks for the emergency stop button(s) in the table.For instructions, see page Reference.

- Safety PLC V74F0040
- R
Emergency Stop - Change
| Equipment Status | Power must be turn OFF.
|
- Disconnect the cable, and change the emergency stop button.
- Connect the cable.
- Perform a test for the replaced emergency stop button. See Procedure Emergency Stop - Check.
Door Guard - Check
| Equipment Status | Power must be turn ON.
|
Note: See Section for the locations of the door guards on the machine.- Identify the door guard(s) to be tested:
- With all the doors closed, for the actual circuit, check that the LED on the Sensor (Adam) is lit with a steady green light.
- Open the door and check that the LED is lit with a steady red light.

- LED
- Sensor (Adam)
- In the electrical cabinet, check that the corresponding input LED is not lit. See the table in Reference for location of the corresponding input LED for each door guard.
- Close the door and check that the corresponding input LED lights up again. See table in Reference for location of the corresponding input LED for each door guard.
- If more than one door guard is to be tested at the same time repeat the procedure for each door guard.
Door Guard Input LED
The reference designation of the door guards and the corresponding input LEDs in the electrical cabinet are shown in the table.
- Safety PLC F03K0014
- IQ11
- IQ12
- IQ13
The reference designation of the door guards and the corresponding input LEDs in the electrical cabinet are shown in the table.| Safety PLC F03K0016 |
| Door Guard | Corresponding Input LED | | Door Guard | Corresponding Input LED |
| F03B2219 | F03K0016: IQ11 | | F03B2213 | F03K0016: I3 |
| F03B1213 | F03K0016:I2 | | F03B2214 | F03K0016: I3 |
| F03B1214 | F03K0016: I2 | | F03B2215 | F03K0016: I3 |
| F03B1215 | F03K0016: I2 | | F03B2216 | F03K0016: I3 |
| F03B1216 | F03K0016: I2 | | F03B2201 (IC) | F03K0016: I3 |
| F03B1201 (IC) | F03K0016: I2 | | F03B2209 | F03K0016: IQ13 |
| F03B1209 | F03K0016: IQ12 | | F03B2210 | F03K0016: IQ13 |
| F03B1210 | F03K0016:IQ12 | | F03B2211 | F03K0016:IQ13 |
| F03B1211 | F03K0016: IQ12 | | F03B2212 | F03K0016: IQ13 |
| F03B1212 | F03K0016: IQ12 | | | |

- Safety PLC F03K0016
- IQ11
- I2
- IQ12
- I3
- IQ13
The reference designation of the door guards and the corresponding input LEDs in the electrical cabinet are shown in the table.
- Safety PLC F03K0024
- I0
- IQ11
- I1
- IQ13
Door Guard - Change
| Equipment Status | Power must be turn OFF.
|
Sensor
- Disconnect the cable, and replace the sensor.
- Connect the cable.
- Perform a test for the replaced door guard. See Section Door Guard - Check on page Door Guard - Check.
Reflector
- Replace the reflector.
- Perform a test for the replaced door guard. See Section Door Guard - Check on page Door Guard - Check.
Door Guard Status Codes
Note: See Section for the locations of the door guards on the machine.The door guards in a protecting circuit are connected in a series. When the door guards are closed, a dynamic signal is sent through the chain of sensors.The LED on the Sensor (Adam) indicates the status of the safe guard:Make sure that the stripe markings for the Sensor (Adam) and the Reflector (Eva) are aligned.
- LED
- Sensor (Adam)
- Reflector (Eva)
Safety PLC - Change
For changing of the Safety PLC, see chapter 7.6.2 Pluto Replacement.Safety Relay Expansion Module
Safety Relay Expansion Module - Check
| Equipment Status | Power must be turn ON.
|
- Identify the safety relay expansion module to be tested. See the placement of the different safety relay expansion modules below:
- Reset the safety system, and make sure that all LEDs on the safety relay expansion module are lit.
- Press an emergency stop button.
- Make sure that none of the LEDs on the safety relay expansion module are lit.
- Reset the emergency stop button and the safety system.
Main Cabinet

- F03K0007
- F03K0008
- F03K0010
- F03K0011
- F03K0012
- F03K0013
- F03K0254
- F03K0255 (NR12)
- F03K1253 (NR12)
- F03K2253 (NR12)
ASU Cabinet

- F03K1223
- F03K2223
CSU Cabinet

- F39K0203
Sprue Remover Cabinet

- V74F0040
- V74F0041
GSU Cabinet

- F29K0002
Safety Valve - Check Function
Assemble Tool
To perform this instruction, it is necessary to assemble the tool.The parts needed in the assembly differs depending on which safety valve needs to be checked.- See the following table for the parts needed.
| Parts used for all safety valves |
| Pressure gauge 90459-7345 | Push-in fitting 351456-0505 | Hose, 3 m 315400-0001 |
| Parts for specific valves |
| Safety Valve | Placement | Hose size, outlet | Components |
| F03K1263 | ASU, NR12 | 8 mm | Hose 100 mm: 315400-0004T-Fitting: 351456-5110 |
| F03K2263 | ASU, NR12 | 8 mm | Hose 100 mm: 315400-0004T-Fitting: 351456-5110 |
| F03K0260 | Filling Section | NA | NA |
| F03K0266 | Carton Section | 12 mm | Hose 100mm: 315400-0010T-Fitting: 351456-5103Reducer: 351456-1108 |
| F03K0269 | Package Section | 14 mm | Hose 100 mm: 315400-0019T-Fitting: 351456-5105Reducer: 351456-1112(Hose 100 mm: 315400-0010T-Fitting: 351456-5103Reducer: 351456-1108) |
| Package Section, NR12 | 12 mm | Hose 100 mm: 315400-0019T-Fitting: 351456-5105Reducer: 351456-1112(Hose 100 mm: 315400-0010T-Fitting: 351456-5103Reducer: 351456-1108) |
- Assemble the Pressure gauge, the Push-in fitting, the Hose, 3 m, the Hose, 100 mm, the T-fitting, and the Reducer.Note: Use the reducer when needed to fit the hose.

- Pressure gauge
- Push-in fitting
- Hose, 3 m
- Reducer
- T-fitting
- Hose, 100 mm
Test the Safety Valve
- Identify which valve is to be checked.
- Put the machine in air off.
- Disconnect one of the Outgoing hose from the safety valve.
- Connect the Hose, 100 mm from the tool to the safety valve.
- Connect the Outgoing hose to the T-fitting.
- Place the Pressure gauge of the tool outside of the machine, positioned so that it is clearly visible.
- Close the door and step up the machine.
- Use the Pressure gauge to check that the air system is pressurized.
- Open the door that corresponds to the safety valve being checked (for filling section, activate the emergency stop).
- Use the Pressure gauge to check that the pressure drops when the door is opened.
- Remove the tool and reinstall all parts in their original positions

- Pressure gauge
- T-fitting
- Hose, 100 mm
- Outgoing hose
Location of Safety Valves
ASU, NR12
F03K1263F03K2263Safety Valve - Change
The following valves are affected by this chapter.| Safety valve | Placement |
| F03K1263 (NR12) | ASU |
| F03K2263 (NR12) | ASU |
| F03K0260 | Filling Section |
| F03K0266 | Carton Section |
| F03K0269 | Package Section |
Safety Valve - Set Soft Start
To set the Adjustment screw to a standard setting, see the following instruction.- Turn the Adjustment screw as far as it goes in to the right.
- Turn the Adjustment screw left according to the table.
| Placement | Non Festo ModelsNo of turns | Festo ModelsNo of turns |
| ASU | 1 | 1 |
| ASU | 1 | 1 |
| Filling Section | 10 | 10 |
| Carton Section | 1 | 4 |
| Package Section | 3 | 4 |

- Adjustment screw
Contactor - Check
| Equipment Status | Power must be turn ON.
|
Damage to equipment.Only authorised and skilled personnel are allowed to perform the instructions described in this chapter.The machine part that are tested can be damaged.
Damage to equipment.Make sure that the correct fuse/overload protection is disconnected.The machine part connected to the tested contactor can be damaged.
- Identify the contactor(s) to be tested. See the tables for corresponding Safety PLC input LED of each contactor:
- Identify which fuse/overload protection supplies the contactor to be tested, see the Electrical Manual.
- Switch OFF the fuse/overload protection supplying the contactor to be tested.
- In the electrical cabinet, check that the corresponding input LED is lit. See the table in Section Reference for location of the corresponding input LED for each contactor.
- Press the Contactor button, and check on the Safety PLC that the corresponding input LED is not lit. Release the contactor and check that the corresponding input LED is lit. See the tables in Section Reference for location of the corresponding input LED for each contactor.
- After the test is completed, switch ON the fuse/overload protection that was switched off in item Reference.

- Contactor button
Contactor Input LED
Safety PLC F03K0014 and F03K0016 (TT3)
- Safety PLC F03K0014
- Safety PLC F03K0016
- I4
- I5
- I6
- I7
- I6
- I7
Safety PLC F73K0200 (TTCU)
- Safety PLC F73K0200
- I7
Contactor - Change
| Equipment Status | Power must be turn OFF.
|
- Disconnect all connected wires, and replace the contactor.
- Reconnect the wires.
- Perform a test for the replaced contactor. See Section Contactor - Check.
Servo Drive Kinetix 6000 – Check
| Equipment Status | Power must be turn ON.
|
Hazardous voltage.After the power is turned off, residual voltage remains in the capacitors inside the frequency converter. Do not touch the terminal immediately after turning the power OFF. Discharge time is at least three minutes from the time power is turned off.Electric shock will cause death or serious injury.

Location of the Servo Drive(s) Racks
- Identify the servo drive(s) to be tested. See the tables for each Rack:
- Step up the machine to Air-On.
- Check that the bus Status indicator has a steady light for all drives.
Carton Section Side 1 Rack- Open the corresponding door for the servo drive to be tested. See table below:
Carton Section Side 2 Rack- Open the corresponding door for the servo drive to be tested. See table below:
Capper Applicator Unit Rack- Open the corresponding door for the servo drive to be tested. See table below:
Package Section Side 1 Rack- Open the corresponding door for the servo drive to be tested. See table below:
Package Section Side 2 Rack- Open the corresponding door for the servo drive to be tested. See table below:
Filling Section Rack- Open the corresponding door for the servo drive to be tested. See table below:
- Check that the bus Status indicator has stopped shining.

Front side view
- Status indicator
- IAM Module
- AM Module
- Step down the machine to air off.
- Turn the electrical supply disconnecting device to position OFF.
- Disconnect the wire at Terminal 5 on the IAM Module module servo drive for the rack where the drive you are checking is located.
- Turn the electrical supply disconnecting device to position ON.
- Step up the machine to Air On.
- Check that the bus Status indicator is blinking on the drive and an alarm shows on the TPOP.
- Step down the machine to Air Off.
- Turn the electrical supply disconnecting device to position OFF.
- Reconnect the wire at Terminal 5 on the IAM Module module servo drive.
- Disconnect the wire at Terminal 7 on the IAM Module module servo drive.
- Turn the electrical supply disconnecting device to position ON.
- Step up the machine to Air On.
- Check that the bus Status indicator is blinking on the drive and an alarm shows on the TPOP.
- Step down the machine to Air Off.
- Turn the electrical supply disconnecting device to position OFF
- Reconnect the wire at Terminal 7 on the IAM Module module servo drive.
- Turn the electrical supply disconnecting device to position ON.
- Step up the machine toAir On, and check that the bus status Status indicator has a steady light on the servo drive.

Top side view
- Terminal 5
- Terminal 7
Servo Drive - Change
For changing of the Servo Drive(s), see chapter 7.5.8 Servo Drive.